Flux and Alloy Batching System

Flux Batching System

A Level 1 system was added to two Basic Oxygen Furnaces to control the addition of the Flux raw materials.  Each furnace has its own weigh system.  Each system has four Burnt Lime bins, a Dolomite bin, a Stone bin, an Ore bin and four weigh scales ranging from 10,000 to 70,000 lbs. of capacity.  This automatic system replaced the manual weighing procedure allowing the operator to perform other duties.

Batch setpoints are sent from a Level II system to the HMI/SCADA.  The Level II system calculates the fluxes using an flux model.  The total batch weight of materials is received from Level II divided up into one to four smaller blow batches.  The operator must accept these batch weights as is or changed them before they are individually weighed and dumped into the furnace at different “oxygen used” setpoints during the blow cycle.  During the blow cycle if Ore was the only material used in a batch it is fed into the furnace at a predetermined rate using the variable speed vibratory feeder on its corresponding weigh hopper.  After the blow cycle is complete the operator has the option to add more material as needed by selecting up to three more batches.

Material weighing order is Dolomite, Burnt Lime, Stone and then Ore.  Ore has the option of being placed on top of the batch or splitting it up and placing a portion of the total on the bottom, between the Burnt Lime and Stone and the rest on top by using operator selectable parameters.

When the furnace blow cycle is complete the setpoints and material weighed totals are sent to Level II for archiving, reporting, costing, and conformance to practice.

Alloy Batching System

Materials used are 75% Silicon, Massive Manganese, Regular Manganese, HBI, Aluminum, Silico, Medium Manganese.  Setpoints are received from Level II and are displayed on the HMI.  The operator will accept or modify these weights and then start the Preliminary Weigh Cycle.  After the furnace blow cycle and the chemistry test is performed the operator will receive chemistry data and updated alloy setpoints for the Final Weigh Cycle.  The material is then dumped and the setpoints and actual weighed material is sent to Level II.

Technologies used:

Allen Bradley 5/30

Wonderware InTouch 8.0

OpenVMS on Alpha

Integrated Process Automation & Control Technologies