Mandrel Furnace
Mandrel Furnace is the optimum solution to heat the mandrels and to cope with the pipe mill lay-out. The best heating performances are achieved by dedicated combustion system or by heat recovery systems which exploit the residual heat from the nearby Re-heating Furnace thus improving the overall sustainability of the Pipe plant.
Overview
Mandrel Furnace is the optimum solution to heat the mandrels and to cope with the pipe mill lay-out. The best heating performances are achieved by dedicated combustion system or by heating system which recover heat from the Re-heating Furnace thus improving the overall sustainability of the Pipe plant.
The furnace can work in continuous or batch mode according to the mill requests, either at the beginning of a new pipe size lot milling operation, either for a single mandrel entering the milling loop. For this purpose, the soaking mode is specifically designed to keep mandrels at the target temperature ready for milling operation.
The temperature uniformity along the length of the mandrel is precisely achieved and it ensures high surface quality for milling performances.
Handling systems are designed to completely automate the mandrel handling operations which are locally or remotely controlled by operator thus ensuring human safety.
In recent years, the proven reliability of Tenova Furnaces is combined to a new generation of advanced features to shift the Furnace into a high technological production unit. The Digital Solutions, New algorithms and Innovative AI models for enhanced process control and proactive management of the assets assure an increased sustainability and profitability of the furnace system.
Technical Data
Provided with indirect burner-fired combustion system or with heat recovery system from waste residual heat from the nearby re-heating furnace.
- Car type or Chain system type
- Continuous or batch heating mode
- Soaking mode to keep mandrels at the target temperature ready for milling operation
- Handling operation completely automated and controlled locally or remotely by operator by dedicated panels.
Benefits and profitability
- Low fuel consumption / Energy recovery from heat residuals
- Improved heating quality through CFD
- NOx and CO emissions according to Best Available Technologies
- Tenova in-house developed burner to cope with process requirement and to enhance sustainability
- Hydrogen and hybrid combustion
Innovation
Tenova has a long tradition in leading edge combustion technology and has developed an interdisciplinary design process including Computation Fluid Dynamics (CFD) modeling which is used for Mandrel Bar temperature uniformity simulation.
Tenova is on the forefront of the innovation: dedicated teams are involving experts for a continuous development of advanced equipment, software solutions and models.
All the equipment are designed and verified under dynamic conditions, which simulate the actual operating condition at plant.
The design on the furnaces is made by in-house software suite Tenova Caltec which includes several tools for :
- 3D heating process modeling
- Mechanical and handling design
- Combustion system design
The results have been validated through the years by dedicated tests and field data collection assuring the reliability of the software’s tool.
Safety
Safety is a priority for Tenova. For this reason, the Safety team is directly involved during the engineering and the execution of all the jobs. It performs risks assessment and reduction measures identification detailed processes.
In order to assure the safety of personnel and the protection of the machinery the following solutions are applied:
- Design of machine done to integrate safety solution
- Area segregation (Fixed Fence, interlocked moveable guards with guard locking).
- Safety Automation control with adequate protection against systematic and random faults (Input, Logic and Output of the command circuits compliant to adequate Performance Level)
- Other Specific reduction measures relevant for the identified risks level.
- Information on Residual Risks by means of Safety Instruction, Safety Warnings signs, etc.
Tenova design can be customized and adapted to local safety regulation for manufacturer (EC Declaration of conformity, EAC Declaration of conformity, OSHA 1910, etc.) and relative standards, e.g. (EN, EN ISO, NFPA, etc.)
Automation
Next generation HMI including the following features:
- User-friendly and intuitive HMI with point and click devices
- Diagnostic features allow to immediately recognize the failure and quickly navigate to the failed equipment
The virtualization of the architecture allows the end users to get the following advantages:
- Drastically increased energy savings
- Drastically reduced downtime in case of HMI client substitution
- Get the High Availability (HA) feature for all the servers and all the clients of the while automation architecture
Safety PLC and Safety Field Equipment as implementation of a detailed risk assessment study, that includes:
- Safety functions identification
- Performance Level / SIL assessment
- Safety Function specification
- Verification and validation process
Environment
Energy transition trends push for the steel industry to start decarbonization as soon as possible, besides pollutant emissions have to be considerably reduced. These technical goals are embraced by Tenova with a dedicated Burners Department which through innovation provides for sustainable solutions. Hydrogen burners, high efficiency burners, low NOX and low CO burners are some of the key elements of the Tenova Burner product portfolio which can offer a wide variety of solutions to respect the strictest environmental standard, to lower CO2 emissions allowing for a sustainable production.
The heat recovery system by Tenova allows for plant efficiency improvement by recovering residual heat in waste gases. Waste-to-heat transfer permits to improve plant sustainability.
Digital
Tenova Furnace Digital Packages “Tenova FDP” purposely designed for re-heating furnaces shift the furnaces from traditional equipment to more efficient and technological production units.
New algorithms and innovative AI models allow for more profitability of the furnace system as follows:
- Higher plant efficiency
- Reduction of costs related to Fuel
- Improve sustainability
- Improve final product quality
- Condition Monitoring Systems for maintenance
From the synergy of Tenova Digital Teams, IT Teams and domain experts, the Virtual Reality approach is now part of the Tenova job execution from sales and engineering activities till the final user dedicated operation and maintenance training sessions.
Tenova is able to provide for the Real-time navigation for model up to 250 Milions of polygons allowing users to interact with virtualized equipment and machines. The interactive experience can be shared with other teams remotely connected from customers and partners offices or from dedicated VR Rooms available at several Tenova’s offices worldwide.
Tenova adVISOR is your remote mentor on site, guiding you through our experts´remote support, interactive documentation and the use of artificial intelligenc algorithms on real time automation data.
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