Category Archive: Uncategorized
Cutting edge engineering solutions that support the iron and steel industry
Tenova‘s multidisciplinary team of specialists have extensive industry knowledge to focus on what is important to you, our customer. Whether your need is to address a current deficiency or to reach a long term future goal, our fume system capabilities can support and improve your plant in the following areas:
- Primary System Exhaust Capacity Issues
Reduced exhaust capacity, fugitive emissions during melting/refining operations, potential for elevated CO levels, draft controls and used energy optimization
- Primary System High Temperature
Increased off-gas energy loss, EAF over-draft capacity, poor combustion chamber design, poor primary system mixing efficiency and low heat transfer efficiency
- Poor Canopy Hood Capture Efficiency
Shallow design-fume bounce out, no fume storage capacity, lack of dedicated exhaust, no internal recirculation flow pattern
- High Temperature in Baghouse
Inadequate canopy hood geometry, exhaust capacity, capture and evacuation efficiency
- Melt shop Ventilation (Heat and Emissions)
Poor melt shop indoor air quality, visibility and potential for elevated CO levels
A better process performance can be achieved through one of the following formats:
- Process studies and assessments, including system performance analysis
- Conceptual designs, including economic feasibility and assessments
- Basic and detail design for competitive contractor bidding
- Commissioning, tune-up and start-up services, including performance testing
Contact Tenova Goodfellow Inc., today to speak to our qualified fume system representatives and to request a quote.
Advanced Process Control Technologies & High Tech Equipment for Greater Profitability
Tenova Goodfellow Inc. (TGI) is a Canadian Clean tech company with locations in Mississauga and Hamilton, Ontario. We supply groundbreaking process control technologies and high-tech off-gas analysis equipment, offering an innovative and intuitive design methodology for the Electric Arc Furnace and Basic Oxygen Furnace steel making industry.
As the “Center of Excellence” for process control technology development within the Tenova Group of Companies, TGI is focused on delivering advanced and integrated clean tech solutions that will improve the energy efficiency for EAF, BOF steel producers. Since the early 2000’s, our technologies and off-gas analysis equipment have achieved dramatic reductions in energy consumption and GHG emissions associated with these industries.
Incorporating real-time off-gas analysis technologies, fume system capabilities with our rugged off-gas process analyzers and state-of-the-art sensors and advanced modules, the end result provides a compelling dual advantage to our customers for hardware and software solutions that result in reduced conversion costs, improved yield and increased productivity.
Our areas of expertise involve several areas:
- Endpoint detection for EAF and BOF steel making using a combination of TGI’s off-gas analysis, process models and innovative sensors to improve carbon, temperature and phosphorous endpoint prediction.
- Chemical energy control and optimization of EAF burners, lances and injectors using our proven closed-loop control methodology that is fully integrated with the plant automation system.
- Automatic tapping control and Intelligent slop detection for BOF steel making to provide operators with greater opportunity to decrease tap time and variability, reducing slag carry-over, as well as mitigate slopping events using lance vibration analysis.
- Fume system control for improved energy efficiency, process performance and related equipment design. Using CFD Modeling, our engineering solutions evaluate performance and aid in design specifications with cost effective solutions for all related equipment and processes.
- Proven off-gas analysis equipment with multi-point capabilities to continuously analyze off-gas from multiple off-gas sampling locations. Unique and innovative sensors for temperature and velocity measurement.
Visit us online at www.tenova.com to learn more about our unique engineering capabilities and innovative technologies.
Visit us online at www.nova-gas.com to inquire about our state-of-the-art gas analysis equipment and sensors.
Tenova to implement NextGen®, iEAF® and WDT® to improve SDI’s EAF process
Mississauga, July 2018 – Steel Dynamics Inc., at Pittsboro (Indiana, USA), is the second SDI plant to place an order for Tenova’s proprietary off-gas process control and water detection technologies. With this order, SDI Pittsboro will install Tenova’s hybrid extractive/laser NextGen® off-gas analysis system, iEAF® dynamic process control system and Water Detection Technology® (WDT®) as a fully integrated solution on the plant’s 100 ton AC EAF.
When fully implemented, Tenova’s combined technologies will bring a number of cost saving, operational, productivity, safety and environmental benefits including reduced electrical & chemical energy consumption, reduced electrode consumption, water leak detection, increased productivity and yield and reduced GHG emissions.
The SDI Pittsboro installation represents the third order of this complete, fully integrated NextGen®, iEAF® and WDT® solution in the United States and will provide SDI Pittsboro with the world’s most comprehensive technology package of off-gas based EAF process control technology.
Tenova’s technological package combines the best in EAF process automation, thermodynamic models, process hardware, innovative temperature/velocity sensor technology, and water detection to offer the steel industry the best in-class EAF furnace control available.
NextGen® is a hybrid laser/extractive off-gas analysis hardware system that delivers faster analytical response times, requires minimal maintenance and reduces hardware and installation costs. NextGen® enables the operator to monitor and control furnace conditions helping to mitigate operational risk.
iEAF® Modules 1, 2 and 3 use NextGen off-gas analysis plus Tenova’s proprietary optical off-gas temperature & flow sensors, a link to the plant’s PLC network and a real-time mass & energy balance to dynamically control and optimize chemical energy & electricity consumption and improve endpoint control to maximize operating cost savings, reduce electrode consumption, increase yield and reduce power on time. .
Tenova’s WDT® provides the most comprehensive off-gas based water detection solution by using NextGen® complete spectrum off-gas analysis including both H2 & H2O vapor to detect and alert operators when abnormally high water levels are present within the furnace.
Installation and commissioning of the system will be done by Tenova Goodfellow Inc., and is expected to be completed in November 2018.
Visit Tenova at the Exposition ~ booth #2615
AISTech 2018 is North America’s Premier Steel Technology Event, to be held at the Pennsylvania Convention Center, Philadelphia, Pa., USA. with more than 7,000 people expected to be in attendance and over 500 exhibiting companies.
Tenova Goodfellow is pleased to be a contributor once again this year at AISTech as an attendee, exhibitor and presenter. AIST gathers the expertise of steel from all over the world, to deliver the most current perspectives on advanced technologies and engineering best practices that will lead to building a sustainable steel industry for the future.
As part of our commitment to steel productivity and profitability, see our schedule of papers:
Monday, May 7
@ 11:00am (Room 204C)
Bringing Innovative Technology to the DRI-Fed EAF Process at Hadeed Saudi Iron & Steel Co.
@ 4:00pm (Room 204A)
Minimizing Production Costs With Tenova’s Enhanced iBOF Optimization Strategy
Tuesday, May 8
@ 4:00pm (Room 114)
Industry 4.0 Leading to the Evolution of Intelligent EAF Steelmaking
Wednesday, May 9
@ 8:30am (Room 112)
EAF Water Detection at Nucor Steel Seattle Inc. Using Tenova’s NextGen Offgas Analysis Technology
@ 9:00am (Room 112)
iConsteel – A Top Charge EAF Revamping Strategy for Reducing Operating Costs, Energy & Particulate
Tenova Goodfellow looks forward to seeing you at AISTech 2018.
Bringing Innovation for the Changing Needs of the Industrial Marketplace
Concentrated on developing unique off-gas analysis equipment, Nova Analytical’s production facility is firmly entrenched in the vision to bring growth through innovation by offering high-tech durable offgas analyzers and advanced sensors that greatly improve operator knowledge in the area of industrial process control.
Part of this vision is to identify and respond to the changing needs within the manufacturing process. It requires agility and innovative thought from your supplier. A configurable approach should include complete alignment between price, production process and end-user experience without sacrificing flexibility.
Read our article, featured in the April edition of gasworld US edition.
Real-time solutions for real-world process needs
At Nova Analytical Systems, we believe that knowledge is power. For over 30 years we have empowered our customers by delivering great off-gas analysis equipment, exceptional customer service support and timely information that you can use to improve your specific process.
Our vast product line is suitable for a wide range of industrial processes and our qualified sales team are skilled professionals that think out of the box to ensure your process runs smoothly.
To introduce you to our many capabilities, click on MORE INFO to search by specific application or by a specific gas.
Haven’t visited us in a while?
We want to remind you of the great advantages that Nova Analytical Systems can offer in your particular industry, please see our headlines below to get re-acquainted with Nova as your off-gas analysis specialist and how our multi-faceted line of analyzers can bring value to your process.
- Landfill gas caused by the breakdown of organic materials can present a significant hazard as an explosion risk and can be damaging to the environment.
- Biogas produced from the breakdown of organic matter through anaerobic digestion is typically high in combustible content.
- Power Generation & Hydrogen Purity maintaining H2 purity will help avoid heat build-up that can cause damage to electric power generators, resulting in dorformity and lost efficiency.
- Heat-Treating & Metal Finishing production requires monitoring for atmosphere, flue gases and ambient air for safety purposes.
- Syngas Production using a gasifier as a source of energy will require gas analysis to help determine the energy content
of the gas before it is burned to optimize the heating value of the gas produced.
- Steel Making processes, whether BOF or EAF, requires reliable off-gas measuring to optimize chemical energy and post-combustion within the furnace.
- Oil & Gas (Petrochemical) is a wide ranging industry with many processes and applications such as marine vapor recovery. Nova’s analyzer solution is a dual-cabinet system with continuous redundant O2 measurement providing greater validity to the sample.
If you have an engineering specification do not hesitate to get in touch with our experienced sales team today.
Click here to speak to one of our qualified specialists.
Tenova supports TimkenSteel’s safety and cost reduction program with NextGen®, iEAF® and Water Detection Technology®
TimkenSteel, Faircrest Plant – Canton, OH, US – has placed an order for Tenova’s proprietary off-gas based technology package including a NextGen® off-gas analysis system, iEAF® dynamic process control technology and Water Detection Technology®. TimkenSteel is a leading producer of carbon and alloyed steel including large diameter SBQ bars and seamless mechanical tubing. Tenova’s equipment will be installed as a fully integrated technology solution on TimkenSteel’s ca. 1 million net ingot tons per year, top charge EAF at the Faircrest Plant.
When fully implemented, the combined technologies will bring a number of operational, safety and environmental benefits including reduced energy consumption, water leak detection, increased productivity and yield and reduced greenhouse gas (GHG) emissions.
Tenova’s technologies are designed to work in tandem to provide a complete process solution that combines leading edge hardware, fundamentally sound process control models, web based automation and the most comprehensive water detection available in the steel industry.
NextGen® is a proprietary hybrid multipoint laser/extractive off-gas analysis system that delivers exceptionally fast analytical response times, requires minimal maintenance and reduces hardware and installation costs.
iEAF® process control software to be installed at Faircrest will dynamically optimize EAF energy consumption, maximize operating cost savings and reduce power-on-time.
Water Detection Technology® uses NextGen® off-gas analysis of both H2 and H2O vapor and proprietary software and is designed to quickly detect and alert Faircrest’s operators when there are abnormally high water levels in the EAF.
TimkenSteel’s installation represents the second order for Tenova of this fully integrated solution in North America and it provides TimkenSteel with the most comprehensive technology package of off-gas based EAF process control technology available in the world.
Mississauga (ON), November 16, 2017: In June 2017, Nova Analytical Systems, a Unit of Tenova Goodfellow Inc., received an order from Ametek Reading Alloys, a division of Ametek Specialty Metal Products, for six (6) DuraNOVA Continuous Process Oxygen Gas Analyzers. Ametek Reading Alloys is a global leader in the production of specialty powdered metals, particularly those with a titanium base. In October 2017, these six units were commissioned by NOVA field service engineers.
Titanium powder has an affinity for oxygen (O2), which creates a potential fire hazard during the powder milling operation process. Historically, to remove the possibility of a hazard developing, an Argon blanket was introduced to provide an inert environment for this industrial application. The inert blanket of gas prevents the powder being processed from reacting with oxygen from surrounding air and sparks created by the mill. For Ametek’s powdered metals process, adding Argon to this process greatly reduced the risk of fire, however, there was still two unknowns; was the drum installed properly and was the oxygen sufficiently purged?
The objective for Ametek using DuraNOVA continuous offgas analysis was twofold: first, validation that the milled powder drum was installed and sealed properly and second, that the system was sufficiently purged of oxygen to allow the milling process to start. There was a need to continuously measure for the presence of O2 in the inert environment created by the Argon. To accomplish this, a DuraNOVA Model 810N4analyzer was installed on each of the six milling cells in the plant. The analyzer O2 control alarm was connected to an interlock that controlled the mill and vibrating table. In this way, the cell cannot be energized until the measured O2 level in the Argon atmosphere is below the analyzer alarm setting.
The DuraNOVA continuous gas analyzer was selected for its simplicity to use, flexibility and overall ruggedness to accurately measure low oxygen concentrations in a very high dust load environment. DuraNOVA Model 810N4 meets the Class 2, Division 1, Group E area rating required for manufacturing that involves powdered metal processes. The equipment is also equipped with automatic calibration and purging functions, which will keep the equipment in a ready-state despite the batch-nature of the process.
Founded in 1953, Ametek Reading Alloy is a leading supplier of Titanium master alloys and highly engineered metal powders for the aerospace, medical implant, military and electronic markets. For more information visit www.reading-alloys.com.
Ametek Specialty Metal Products is a global leader in the production of metal powders, master alloys, clad metals, specialty wire products, metal strip, engineered shaped components, thermal management products, foil, and precision strip & coined parts. These materials are used in a variety of applications, including automotive, aerospace, micro-electronics, appliance, lock & hardware, telecommunications, marine, medical and general industrial. For more information visit www.ametekmetals.com
Tenova, a Techint Group company, is a worldwide supplier of advanced technologies, products, and services for the metals and mining industries providing innovative, integrated solutions for complete process areas. Tenova Group employs around 3.500 employees in 24 countries on 5 continents. For more information visit www.tenova.com
Nova Analytical Systems, a Unit of Tenova Goodfellow Inc., has designed and manufactured dependable gas analysis equipment for over 35 years. Nova offers portable gas analyzers, continuous gas analyzers and sample conditioning equipment for a diverse range of traditional and emerging combustion intensive industries in various global regions. For more information visit www.nova-gas.com
Tenova Technologies, NextGen®, iEAF® and Water Detection exceed expected benefits in the areas of reduced operating cost, energy consumption and safety.
Mississauga, 18 September 2017 – Nucor Steel Seattle, Inc., has officially signed off on Tenova’s Water Detection System® (WDS). The System was approved based on controlled testing and successful detection of actual EAF water leaks.
These results confirmed that the WDS met the plant’s requirements to detect and alert plant operators when higher than normal water conditions were present in the EAF. Furthermore, the WDS has also demonstrated minimal false alarms even in Seattle’s highly variable seasonal weather conditions.
In addition, the NextGen® + i EAF® project previously commissioned in April 2016, surpassed Nucor Steel Seattle, Inc.’s expectation for quantifiable and sustainable improvements in monthly process consumptions and operating costs: average monthly furnace consumptions were significantly decreased in the following areas: 5% electrical, 1.5% oxygen, 11.5% natural gas, 7.5% injected carbon and 32% charge carbon.
Complete system performance has more than doubled from the original estimated savings target determined at the start of the project with total electrical and chemical energy costs per ton of steel being reduced by over 6%.
Tenova’s i DRI® technology achieves demonstrated performance in the areas of yield, productivity, electrical and Power on Time (PON)
Mississauga, 2 August 2017 – Hadeed Saudi Iron & Steel Company has signed a final acceptance certificate for the Tenova’s i DRI® project for the successful delivery of the Furnace Optimization System on DRI fed EAF 5 at Hadeed Plant.
The i DRI® technology project at Hadeed has demonstrated performance in the areas of 1.42% yield increase, 4.1% productivity increase, 3.23% reduction on electrical consumption and 1.6 min reduction on Power on Time (PON).
As applied to the DRI process, the models are responsible to calculate the most important parameters used by the iEAF® control modules. Working alongside the plant PLC, performance of the system was achieved through validation of several fundamental outputs, inclusive of: off-gas measurements using EFSOP® technology; a downstream analyzer; temperature and off-gas flow sensors; furnace and auxiliary service automation; process modeling for real-time mass and energy balance; chemical energy control and optimization of the oxygen lances; and DRI feed rate control.
Tenova Goodfellow Inc. (TGI) is the market leader in providing “intelligent” process control technology to the EAF and BOF steel industry. Our breakthrough technologies are designed to reduce cost, improve yield and productivity and reduce GHG emissions. Nova Analytical Systems, a Unit Company of TGI, design manufacturers advanced off-gas analysis equipment and innovative sensors that are applicable for a diverse range of traditional and emerging industrial markets. Together, we provide our customers the complete package of software and hardware for all their process needs.