s2 ranger slag-analyzer solution
TRANSCRIPT
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S2 RANGER Slag-Analyzer Solution
Alexander Seyfarth
BRUKER AXS
May 2008
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EAF Slag Requirements
� Compatibility with the refractories - MgO saturated since most slag lines consistof magnesia-carbon refractories
� Good foaming properties - Foam at the right time and long enough
� Lower Energy consumption and metal loss
� Controlling additive (Dolomite, Lime , Coal, ProSlag™) amounts therefore cost!
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Why slag analysis?
� New furnace refractory linings enable more heats between maintenance intervals
• E.g. dry monolithic bottom material instead of brick
• Specialized zone based lining with customized bricks
� Slag is used to protect refractory material
• Less repair and downtime
• More heats in combination with refractory optimization
� Slag properties impact energy consumption
� Selection of additives to create effective slag
• Additives for Mg and Ca
• Additives for C
• Additives for Al, Si flux
� Slag optimization for better alloy control
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Courtesy of BAKER Refractories
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Pay back of slag control
� Use of monolithic patching material decreased from 7.0 to 5.5 lb. per ton of steel produced.
� Gunning material consumption decreased from 2.4 to 0.7 lb. per ton.
� Furnace brick life doubled
� The energy consumption per heat decreased from 339 to 323 kWh/ton.
� Tons per hour increased from 113 to 119.5
With the RIGHT slag control this WOULD have been your
PAYBACK
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EAF Slag compositionAnalytical requirements
% MgO 8% CaO 43% FeO 26% MnO 6% Al2O3 4% SiO2 13
Fluxing Oxides
Refractory Oxides
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New Challenges!
�Number of heats / shift increased
�Time per heat lower
�Accuracy for Al, Si, Mg important!
5 10 15 20 25 30 35 40 45 50
2
4
6
8
10
12
14
16
% M
gO
L
C2S+
MW+L
MW + L
C2S+L
B3 = 1.61600°C (2912°F)
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What is needed ?
� Time to result from sample to result < 20 min!
• Get the data while heat is still ON!
� Repeatable and fit for purpose results
• Accuracy for Mg and Al, Si important
• Rations to be calculated with analysis
� Results transmittable into Level 2 system
• Metallurgist needs data to calculate next heat!
� Rugged all in one design
• One plug! No cables! No PC
� Easy to use
• 3rd shift capable ☺
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Analytical Technology
� Metal analysis now only done by OES
• Slag analysis via OES not effective and problematic
• Metal analysis including N and C!
� Slag analysis by XRF very effective !
• Used since 1970’s
• WD and ED XRF techniques available
� WD XRF had sensitivity AND resolution for Mg Al and Si
• WD XRF is used since the 70’s
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XRF X-ray Fluorescence AnalysisCharacteristic X-rays
Energy of X-ray photons
� element
� qualitative analysis
Number of X-ray photons at a given energy
� concentration
� quantitative analysis
X-ray
tube
Sample
E , N
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X-ray Fluorescence AnalysisWavelength-dispersive XRF (WD-XRF)
� an analyzer crystal separates the various wavelengths λ (energies)
� the detector records only the number N of X-ray photons at a given wavelength (energy)
X-ray
tube
Sample
DetectorN
λλλλ
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WD XRF technology
� Process grade WDXRF
• LAB setting -> smaller unit
• less demand on infrastructure
• Direct loading for uptime
• Auto samplers…
• Backup for OES (steel!)
� BUT not in the control room…
• Too big!
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X-ray Fluorescence AnalysisEnergy-dispersive XRF (EDX , ED-XRF)
The detector is used to record both
� the energy E and
� the number N
of X-ray photons
X-ray
tube
Sample
Detector
E , N
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ResolutionSDD vs. Si Pin
� SDD (145 eV) compared to Si-PIN (250 eV)
Cl K αααα
S KααααCa Kαααα
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Resolution is not all!Standard Detector vs. Bruker XFlash®410
Energy resolution of Cu Kα at different count rates.
XFlash SDD in S2 Ranger 4th Generation
standard detector (SDD)
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010
020
030
040
050
060
070
080
090
010
00
110
012
00
130
014
00
Cps
Si
KA
1
Si K
B1
Al K
A1
Al K
B1
Mg
KA
1
Mg
KB
1
1.11.21.31.41.51.61.71.8
KeV
Separation and sensitivity at 100.000 cps
Si
AlMg
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Sample – taken manual or by robot
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Crush to ensure homogeneity
BEFORE
AFTER
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Sample preparation in 3 steps Dose – Grind – Press
�Crush sample
�Grind sample
�Press powder into tablet
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Remove “iron” from powder
� Second quick removal by magnet
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Sample preparation repeatability10 pellets from crushed material
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Accuracy and stability (EAF) (n=10 on same sample)
E A F Compound
Avg. error of calibration
(SEC) (wt%)
Stability as Std. Dev.
(wt%) Al2O3 0.12 0.03 CaO 0.58 0.04 Cr2O3 0.04 0.01 FeO 0.13 0.05 MgO 0.23 0.13 MnO 0.12 0.01 P2O5 0.15 0.01 S 0.005 0.00 SiO2 0.71 0.05 TiO2 0.05 0.01
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Long term stability ….
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S2 SLAG-ANALYZER ED XRF with XFlash™
� All in ONE design
� Pd X-Ray tube operated up to 50Watts, air cooled
� Silicon Drift Detector 4th generation XFlash with 145 eV at 100.000 cps (MnKA1)
� Integrated Vacuum pump
� Direct Access Sample compartment
� TOUCHCONTROL™
� Built in Printer
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Direct Access for samplecleaning no problem!
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Accuracy and Repeatability
E A F Compound
Avg. error of calibration
(SEC) (wt%)
Stability as Std. Dev.
(wt%) Al2O3 0.12 0.03 CaO 0.58 0.04 Cr2O3 0.04 0.01 FeO 0.13 0.05 MgO 0.23 0.13 MnO 0.12 0.01 P2O5 0.15 0.01 S 0.005 0.00 SiO2 0.71 0.05 TiO2 0.05 0.01
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Connectivity..Networked via TCP/IP
On Demand via WEBEXOn Demand via WEBEX
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All in one Design
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S2 RANGER SLAG-ANALYZER
� Time to result from sample to result < 20 min?
� Repeatable and fit for purpose results
� Easy to use
� Results transmittable into Level 2 system
� Rugged all in one design
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�Together we can make it happen in your plant!
www.bruker-axs.com
Together we can make it happen in your plant!