Level 2 System for Reheating Industrial Furnaces
Representing significant progress in reheating process optimization, Tenova’s Sethlans Level 2 system is part of a new generation of sustainable industrial furnaces. Performance gains and eco-sustainability are targeted in the Level 2 system along with industrial efficiency and better quality.
Overview
An approach to achieving a more sustainable low-carbon economy along with performance gains. That’s what Tenova Sethlans Level 2 System represents. In a word: eco-innovation. Tenova Sethlans is a massive improvement in steel production environmental performance and a powerful tool to reduce fuel costs and increase the quality of the reheated steel.
Technical data
Tenova Sethlans’ application plants:
- Walking beam and pusher furnaces
- Roller hearth furnaces
- Direct firing furnaces in annealing and galvanizing lines
Tenova Sethlans’ functions for walking beam, pusher and roller hearth furnaces:
- Online thermal modeling for slabs and thin slabs, blooms, squared and round billets, beam blanks
- Predictive calculation of temperature setpoints
- Automatic management of mill and furnace stillstands
- Furnace pace rate modeling
- Adaptive feedback from the mill pyrometer
- Furnace thermal balance
- Production and thermal reports
Tenova Sethlans’ functions for direct firing furnaces designed for annealing and galvanizing lines:
- Online thermal modeling for strips
- Model predictive control of gas flow setpoints in both steady and transient state
- Adaptive feedback from the line pyrometers
- Production and thermal reports
In walking beam, pusher and roller hearth furnaces, Tenova Sethlans helps you achieve the following targets:
- A decrease in fuel consumption
- A consequent decrease in CO2 and NOx emissions
- A decrease in scale production with a direct effect on yield and overall productivity improvement.
- A precise control of the required dropout temperature through online modeling, predictive control and furnace pace rate modeling
Reduce fuel consumption by up to 5% through online modeling, predictive control and automatic stillstand management with a consequent improvement in CO2, NOx emission and scale formation. Further performance gains can be attained through the furnace pace rate modeling by granting the desired dropout temperature even during the transition from thin to thick load and by managing different furnaces feeding the same mill line. Worldwide references are available.
In direct firing furnaces designed for annealing and galvanizing lines, Tenova Sethlans helps you fulfill the following targets:
- Maximize the strip length achieving the required temperature targets
- An automatic adaption to variable line speed
Strip thick-thin and strip thin-thick transitions are optimized to get the maximized length of in-tolerance material through model predictive control. Line speed variations are absorbed through model predictive control giving the plant further performance gains.
After Sales Service & Support is available for any type of Tenova Sethlans application. Tenova Sethlans engineers can remotely connect to the system or help the customer improve the performance of the system on-site.
Innovation
3D-Modeling for any type of charge by walking beam and pusher furnaces for a better estimation of the charge temperature and of the skid effect
Furnace pressure setpoint adaption through machine learning algorithm running on Tenova’s cloud platform
Model predictive control by DFH strip furnaces with gas flow setpoints for an increased strip length inside the desired strip temperature tolerances
Automation
Tenova Sethlans is the Level 2 layer of Tenova’s reheating furnaces multilevel automation control system. Its main automation features are:
- Client/server architecture with Windows Server, allowing an unlimited number of operator’s and engineer’s HMI clients to connect to Tenova Sethlans server tasks without any disruption
- Level 1 PLC layer and edge computing connection through OPC and OPC UA technology
- Customer’s Level 2 and Level 3 connection through database or TCP/IP messages
- Database technology for fast retrieve of historical and report data
- Availability on Virtual Machines running in a wholly virtualized platform with backup and swift replication of any installed VM avoiding massive downtimes and disruption
Environment
A fuel consumption decrease and the consequent reduction in CO2 and NOx emissions are Tenova Sethlans’ main goals. Online thermal modeling for any kind of charge (slabs, blooms, billets, beam blanks, etc.), predictive calculation of temperature setpoints and automatic management of mill and furnace stillstands are keenly designed and commissioned to get to up to 5% fuel savings with a consequent improvement in CO2, NOx emission.
In addition to that, Tenova Sethlans’ design and implemetation on Virtual Machines is highly recommended to scale up power energy savings
Digital
Data analytics is nowadays a powerful tool to get the best performance from a reheating industrial furnace. Tenova Sethlans is one datasource of data analytics performed by Tenova Edge®, Tenova’s computer edge, and the artificial intelligence solutions running on Tenova’s cloud platform. Tenova Sethlans makes available process variables like oxygen concentration, furnace and charge temperatures, gas and air flows to Tenova Edge® for subsequent processing made by AI algorithms and calculation of KPI values
