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extremely accurate flow meters . Rosemount E-Series magnetic flow meters from Emerson deliver industry-leading performance , providing cooling water measurement accuracy to 0.15 % at target flow rates . This enables faster and more reliable leak detection , and improved furnace performance . and throughput , and significant reductions in energy costs and product quality variation . DRI is a hybrid chemical process and therefore more like a chemical plant than a traditional blast furnace . An integrated control and safety system ( ICSS ) is the most suitable platform for such applications .
The latest wireless temperature transmitters eliminate cable and conduit damage , leading to better temperature control , reduced maintenance costs and shorter batch times .
The standardisation of measurement devices – or the use of multivariable instruments , with the same model for different types of measurements , such as differential pressure , flow or level – provides a range of benefits . It helps to reduce costs , engineering and service efforts during all project design phases , and reduces installation complexity , process interventions , potential leakage points and safety issues . Nonintrusive measurement devices can be deployed to mitigate these types of problems , and the use of industrial wireless networks and sensors can dramatically lower installation time and costs compared to wired alternatives .
Optimising process control and safety
To make their plants as safe and efficient as possible from startup , green steel manufacturers must ensure that processes are operating at their optimal point , which requires excellent process control . The benefits of process optimisation can include increased equipment availability
A modern , advanced ICSS provides the high performance required for the complexity of the DRI process , while its versatility , flexibility and speed enable optimal plant operation . An ICSS simplifies hardware requirements and logic programming , and significantly reduces the complexity of future engineering modifications and testing .
Control valves also play a critical role in optimising the efficiency of the DRI process , by making it possible to selectively lead the coke oven gas , fuel gas , steam , combustion air and flue gases according to the stage of the operating cycle , as well as operating the closedcircuit water system . However , a range of severe service and variable process conditions – including cavitation , abrasion , high environmental noise , high temperature and high pressure drops – make DRI a challenging application for valves . Selecting valves that operate reliably despite these conditions is therefore a key consideration .
Automation suppliers can provide control valves with trims that mitigate cavitation and prevent critical asset failure ; avoid trim and valve body erosion ; reduce environmental noise and control pressure and temperature reduction .
Gas detection
DRI and EAF processes generate various toxic and combustible gases that contain carbon monoxide and hydrogen , which creates obvious safety and environmental risks . It is therefore vital for organisations to ensure that reliable gas detection systems and ventilation systems are in place . Automation technology suppliers provide wired and wireless point gas detection , open path gas detection and ultrasonic gas leak detection solutions to support green steel producers . These gas detection safety solutions are designed to continuously monitor and detect gas leaks before they lead to harmful conditions , helping to keep personnel and sites safer .
34 Green Steel World | Issue 9 | November 2023