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Electroslag remelting process

Process description

Electro-slag re-melting produces steel with a high purity and precise, flawless structure. A solid raw steel block is slowly fed into a hot slag bath (1500°C).  An arc is ignited between the steel block and the slag bath. As a result, the steel block melts and drips through the slag, leaving impurities such as sulphur and non-metallic residues in the slag. After solidification of the drops, a purified, re-melted steel block is formed under the slag.

In the pressurised electro-slag re-melting process (DESU), in addition to the slag, an inert gas provides protection from oxidation.  

Oxipyr burner for block pre-heating

The raw steel block needs to be pre-heated before the actual re-melting process. The oxyfuel burner is an energy efficient solution for this application.   

Application example of Oxipyr burner for block pre-heating

This example compares data from oxyfuel processes and electrical preheating. The specified costs include equipment and wear parts

 

Electric

Oxyfuel

Savings [%]

Power [kW]

60

90

-50

Time [min]

250

160

36

Costs [%]

100

48

52

 

Gas Application

  • Oxyfuel-process for block pre-heating 
  • Addition of inert gas during DESU process

In the oxyfuel process, the combustion processes are carried out by means of an oxygen burner (oxy-fuel burner), which is operated with pure oxygen or with oxygen-enriched air as oxidant. Messer has developed the Oxipyr burner family for this purpose. Compared to burners that use air as an oxidant, oxy-fuel burners have a number of process technology advantages:

Advantages:

  • Higher combustion efficiency
  • Higher melting performance
  • Faster heating-up times
  • Lower fuel consumption
  • Higher processing temperatures possible
  • Faster reaction speeds
  • Lower exhaust gas levels
  • Less dust
  • Lower emissions
  • Lower production costs

Messer SOlution

In addition to the gases required for your process, Messer offers a variety of equipment for its optimisation under the brand names Oxipyr and Oxijet. 

In order to select the optimum system, experts from Messer first carry out a comprehensive process analysis. Following calculations and basic engineering, suggestions are made for optimisation and further procedures.

Oxipyr – Burner Technology

The characteristics of the burner types are multi-faceted and range from low to high momentum burners, oxyfuel to oxygen/air mixing burners and burners for different fuels or fuel combinations. The systems are controlled manually, semi- or fully automatically following compositions or temperature.

Oxipyr

Fuel

 

Burner protection

Flame

Burner Technology

gas

liquid

solid

low NOx

refractory material

traversing device

cooling

monitoring

ignition

Oxipyr – P

X

 

 

 

X

X

X

X

X

Oxipyr – F

X

X

X

X

X

X

X

X

X

Oxipyr – Flex

X

X

X

X

X

X

X

X

X

Oxipyr – Air

X

X

X

X

X

X

X

X

X

Oxipyr – SVNR

X

X

X

X

X

X

 

X

X