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Ladle preheating

Process Description

Ladles or other containers are used to transport liquid metal which cannot reach the next process steps via gutters. These ladles are pre-heated to extend the life of the refractory lining and avoid costly over-heating of the metal bath. Pre-heating temperatures of up to 1200°C are uneconomic with cold air burner systems, and temperatures above 1200°C are difficult to achieve.

Ladle-preheating station

In the case of oxyfuel burner systems there is a distinction between their use for pre-heating ladles which are circulated during the production process; and for drying new ladles made of refractory material.  The reason for this is the different heat transfer mechanisms at different temperature levels. 

Advantages of Oxipyr burner systems at a glance:

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

Newly delivered ladles must be heated slowly following heating curves specified by the refractory material manufacturers. Smoke and odor problems caused by the expulsion of the refractory binders can be prevented by internal post-combustion. 

Drying newly delivered ladles: 

This is carried out at the lower temperature range using oxyfuel with air enrichment, or exhaust gas recirculation.  When refractory binders start being expelled, additional oxygen is used for internal post-combustion in the vessel. At the end of expelling the refractory binders, stoichiometric oxyfuel combustion is used.

Natural gas savings with oxyfuel:           30% - 40%

Pre-heating of ladles during production cycle:

Rapid, energy-conserving stoichiometric oxyfuel combustion  

Natural gas savings with oxyfuel:           40% - 70%

Application Oxipyr-burner for pre-heating: 

Time

Air burner

Oxyfuel

[min]

[kW]

Temp [°C]

[kW]

Temp [°C]

75

1700

910

530

1150

120

1700

1050

400

1290

210

1470

1140

400

1320

Gas-Application

Oxygen burner technology

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 flame for ladle preheating

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 devices

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