Furnance Surface

 DANIELI CENTRO COMBUSTION CHAPTER 1
CHAPTER 1
TECHNICAL DESCRIPTION
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DP07XL-JC33-G0000-FB100-01_00.doc Use & Maintenance Manual Page 1/22
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF DANIELI CENTRO COMBUSTION SPA NOT DISCLOSABLE, NOT REPRODUCIBLE. ALL RIGHTS RESERVED.
1 TECHNICAL DESCRIPTION
Customer and plant location EMIRATES STEEL INDUSTRIES

U.A.E.
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Commissioning year 2011

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Furnace type
see drawing DP07XL-JC33-M1100-FD001 LAYOUT – PLAN VIEW

DP07XL-JC33-M1100-FD002 LONGITUDINAL SECTION
DP07XL-JC33-M1100-FD003 CROSS SECTION
DP07XL-JC33-M1100-FD004 CROSS SECTION
The furnace is a: walking beam furnace (top and bottom fired) and is divided into several combustion
control zones.
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Dimensions .
Roll to roll external length 39,975 mm

Wall to wall inside length 32,540 mm
Wall to wall inside width 13,100 mm
Max Height From Pass Line Preheating Top Zone 2,200 mm
Max Height From Pass Line Preheating bottom Zone 2,100 mm
Max Height From Pass Line Heating Top Zone 2,200 mm
Max Height From Pass Line Heating bottom Zone 2,100 mm
Max Height From Pass Line Soaking Top Zone 1,500 mm
Max Height From Pass Line Soaking bottom Zone 2,100 mm
Pass Line +5,770 mm
Stack height +75,000 mm
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Product Bloom and beam blanks
- materials Low carbon Steel, Medium carbon Steel, Low alloy

Steel
- Cold Conditions
Type Unit Bloom BB1 BB2 BB3 BB4 BB5

- Thickness mm 220 350 250 435 350 460
- Width mm 350 430 480 500 670 1050
- Length m 12 12 12 12 12 12
- Metric weight kg/m 605 649 538 925 814 1615
- reference charge 460 x 1050 x 12,000 mm
(See also dwg:
- DP07XL-JC33-M1100-FD011 Charging Scheme-Plan View;
- DP07XL-JC33-M1100-FD012 Charging Scheme-Longitudinal view
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Production
- nominal production 250 t/h
- charging temperature 20°C (hot charging 500°C)
- Reference discharging temperature 1,250°C
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The specific heat consumption
The specific heat consumption with continuous furnace operation, heating beam blank 460
x 1050 x 12,000 mm of low carbon steel grade from reference charging temperature
(20 °C) to nominal discharging temperature (1,250 °C), with the reference throughput
(250 t/h), firing natural gas with 5% excess air is: 279 Kcal/Kg max.
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Plant configuration - Furnace configuration
The plant configuration is:
- Charging area
- Furnace
- Discharging area
- Recuperator/fans/stack area
Construction characteristics
. charging frontal, on external roller way and charging machine

. discharging frontal, on external roller way and kick-off machine
. handling hydraulically driven walking beam mechanism
Bloom/ beam blank positioning one row
. number of beams . at charging side: nr. 5 (fixed); nr. 4 (walking)
. at discharging side: nr. 6 (fixed); nr. 4 (walking)
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2 HEATING SYSTEM
The heating system is designed in order to give complete independence to each thermal
control zone.
The heating system is composed by:

- Combustion air system
- Combustion air fan
- Recuperator (bundle tubes, convection type)
- Fuel system
- Burners (side, frontal and radiant)
- Instrument air system
- Waste gas system
- Duct
- Furnace pressure control valve
- Stack
See below for detailed description of equipment
Combustion control : PLC regulation with Level 1 supervision; Level 2 optimisation

The heating system is split into 9 (nine) combustion control zones, as follow:
1 Top Pre-heating zone 1- lateral MAB burners with PHL firing logic
2 Bottom Pre-heating zone 2– lateral MAB burners with PHL firing logic
3 Top Heating 1 zone 3 - lateral MAB burners with PHL firing logic
4 Bottom Heating 1 zone 4 – lateral MAB burners with PHL firing logic
5 Top Heating 2 zone 5– lateral MAB burners with PHL firing logic
6 Bottom Heating 2 zone 6– lateral MAB burners with PHL firing logic
7 Top right Soaking zone 7- Radiant burners with modulated firing logic
8 Top left Soaking zone 9 – Radiant burners with modulated firing logic
9 Bottom Soaking zone 8 - frontal MAB burners with PHL firing logic
The heating system is shown on the following schematics:

- Nitrogen manifold see dwg. DP07XL-JC33-P7300-FD001
Nitrogen(zone 1÷2) see dwg DP07XL-JC33-P7300-FD002
Nitrogen(zone 3÷4) see dwg. DP07XL-JC33-P7300-FD003
Nitrogen(zone 5÷6) see dwg. DP07XL-JC33-P7300-FD004
Nitrogen (zone 7÷9) see dwg. DP07XL-JC33-P7300-FD005
Nitrogen (zone 8) see dwg. DP07XL-JC33-P7300-FD006
Nitrogen (Pilots) see dwg. DP07XL-JC33-P7300-FD007
- Natural gas(manifold) see dwg. DP07XL-JC33-P7600-FD001
Natural gas (zone 1÷2) see dwg. DP07XL-JC33-P7600-FD002
Natural gas (zone 8) see dwg. DP07XL-JC33-P7600-FD006
Natural Gas (Pilots) see dwg. DP07XL-JC33-P7600-FD007
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- Combustion air manifold see dwg. DP07XL-JC33-P7400-FD001

Combustion air (zone 1÷2 ) see dwg DP07XL-JC33-P7400-FD003
Combustion air (zone 3÷4) see dwg DP07XL-JC33-P7400-FD004
Combustion air (zone 5÷6) see dwg DP07XL-JC33-P7400-FD005
Combustion air (zone 7-9) see dwg DP07XL-JC33-P7400-FD006
Combustion air (zone 8) see dwg DP07XL-JC33-P7400-FD007
Combustion air (pilots) see dwg DP07XL-JC33-P7400-FD008
Combustion air (f.ce instruments ubication) see dwg DP07XL-JC33-P7400-FD002
- Instrument air see dwg DP07XL-JC33-P7400-FD061/FD062
2.1.1 Combustion air system
Combustion air fan: See dwg. DP07XL-JC33-M1468-FD002
Two centrifugal fans (one in stand-by) with flexible coupling and integral frame are
foreseen for the combustion air, close to the recuperator.
The fan shafts are placed on two grease lubricated support bearings.
The main features of the fans are the following:
Flow rate Nm3/h 120,000

Pressure daPa 1,200
Speed RPM 1420
Installed power kW 800
Noise at 1 m dBA 85
Pressure/flow control inlet vane and
VVVF
The combustion air fans provide also cold air necessary for cooling the shaft of the furnace
pressure control valve
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Pilot Air Fan
One centrifugal fan with flexible coupling and integral frame is foreseen for combustion
air to feed pilot burners.
The main features of the fans are the following:
Flow rate Nm3/h 500

Pressure daPa 800
Speed RPM 3000
Installed power kW 7.5
Noise at 1 m dBA 85
Pressure/flow control -
Recuperator
See dwg. DP07XL-JC33- M1468-FD001_001, DP07XL-JC33- M1468-FD001_002 )
A convection type recuperator for the combustion air preheating is placed in the waste
gas duct.
The recuperator is counter flow type.
The recuperator elements are tube bundle type suspended from the top and supported by
a steel structure.
The recuperator casing is internally lined and equipped with man holes in order to facilitate
the inspection.
The recuperator is protected against waste gas overheating by means of cold air dilution
injected upstream the recuperator itself. A proper control valve controls the dilution air flow.
The recuperator is protected against combustion air overheating by means of a bleeding

valve placed on the combustion air manifold, downstream reku.
Its modulated opening corresponds to a proportional increasing of the air flow through the
tube bundles.
Main features of recuperator are reported in the following table:
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Item Data Unit Case A Case B Case C …

Nom inal Max
250 tph @ 100% 250 tph @ 90% 250 tph @ 90%
Cold charge C old charge H ot charge …
1 Fuel type (characteristics) - Natural Gas
(NHT=8550 kcal/Nm 3; waste gas =1,24 kg/Nm3 )
(Air/Fuel = 10,07; Waste Gas/Fuel=11,06; e=5% air excess)
2 Type (parallel / counter flow) - counter flow
3 Waste gas duct arrang.t (horiz. / vertical) - horizontal
4 Comb. air pipes arrang.t (horiz. / vertical) - vertical
5 Supporting system - suspended
6 Beam lining [%] 100 90 90 …
7 Production [t/h] 250 250 250 …
8 External atmospheric pressure [daPa] > 10200
9 Waste gas flow upstream dilution [Nm 3/h] 96900 104400 82800 …
10 Waste gas temp. upstream dilution [°C] 760 760 810 …
11 Dilution air flow [Nm 3/h] 0 0 6625 …
12 Waste gas flow upstream recu [Nm 3/h] 96900 104400 89425 …
13 Waste gas duct upstream recu (internal) [mm] 3250
14 Waste gas temp. upstream recu [°C] 760 760 760 …
15 Waste gas temp. downstream recu [°C] 371 375 370 …
16 Waste gas duct downstream recu (internal) [mm] 3000
3
17 Air flow [Nm /h] 83000 89500 69800 …
18 Air temp. upstream recu [°C] 20 20 20 …
19 Max air static pressure before recu (relative) [daPa] 1200
20 Air temp. downstream recu [°C] 530 525 530 …
21 Hot air bleeding [Nm 3/h] 0 0 6500 …
22 Total air flow [Nm 3/h] 83000 89500 76300 …
23 Pressure loss waste gas side [daPa] 10 12 9 …
24 Pressure loss air side [daPa] 290 320 250 …
25 Maximum operating temperature (w.gas/air) [°C] 850 / 550
26 Emergency temperature (max 4*30' /day) [°C] 870 / 560
27 Warranted performances - Air temp: 530 °C ±1% (ref.:A); p losses: 12/320 daPa ± 5% (ref.:B)
28 Exchanged heat in recu to air [kW] 15852 16914 14568 …
…
29 Heat exchange factor [W/m 2 °C] 46,27/28,07 48,39/29,52 43,74/26,50 …
…
Geometric features and speed

30 Air inlet nr. 3
31 Inlet ND [mm] 900
32 Air speed [m/s] 12,96 13,98 11,92 …
33 Air outlet nr. 3
34 Outlet ND [mm] 1300
35 Air speed [m/s] 17,02 18,24 15,65 …
Materials: rows numbered acc. to waste gas direction

36 Number of parallel recuperators 3
37 Pack 1st 2nd 3rd 4th
38 Rows nr. 16 17 … …
39 Tubes nr. each row 32 32 … …
40 Tubes pitch 74/79 74/74 … …
41 Tubes Layout (in line / quincunx) in line in line … …
42 Total tubes Nr. for each pack 512 544 … …
43 Total tubes Nr. 3168
44 Materials (2) 1.4510/1.4720 St 37 … …
45 Tubes: ND x Thickness x Length [mm] 44,5x2,6x3550
46 Tube type (seamless or welded) welded welded … …
47 Internal spirals [m2] 168,2 0 … …
48 External surfaces of 1 tube [m2] 0,5035 0,4963 … …
49 Pack surface [m2] 257,8 270 … …
50 Total surface [m2] 1583,2
51 Total weight [kg] 40500
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Fuel system
The fuel system and all related control and safety devices are designed for firing natural
gas (see DWG. DP07XL-JC33-P7600-FD001÷FD007)
Burners
Installed burners are lateral (top and bottom preheating and heating zones),radiant (top
soaking zones) and frontal type (bottom soaking zone).
Burners are designed for firing natural gas and preheated air.
The special design of these burners, allows to work in the wide operating range (1÷8).
Each radiant roof burner is equipped with:
- Calibrated natural gas orifice plate
- Stainless steel air baffle
- Burner block
- Fuel gas lance
Each lateral and frontal burner is equipped with:
- Calibrated natural gas orifice plate
- Air diffuser
- Fuel gas lance
GENERAL REMARS: All burners are low NOx emission type; D.C.C. is able to guarantee a
max level of NOx emission in the waste gas system of 150 ppm with 5% O 2.
REMARK: The furnace temperature operating ranges are always higher than self-ignition
temperature.
ZONE# 1,2,3,4,5,6 and 8, the lateral burners are equipped with the following main devices:
 Manual shut-off valve
 Orifice plate
 Flow control valve
 Shut-off valve (on gas circuit)
 Manual shut-off valve per each burners
 Automatic Shut-off valve per each burners
ZONE# 7 and 9, the radiant roof burners are equipped with the following main devices:
 Manual shut-off valve
 Orifice plate
 Flow control valve
 Shut-off valve
 manual shut-off valve per each burners
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Thermal capacity of the zones
The most important purpose of the furnace is to suitably adapt the variable conditions such
as:
- Different dropout temperatures,

- Different product
- Recover of Mill delays
For all these reasons the furnace has to be thermally suitable dimensioned to guarantee the
purpose, in this case the thermal installed capacity is higher than the required one.
The nominal heat input required to heat the stock in nominal conditions, from 20°C to
1,250°C, at 250 t/h with 5 % access of air, 100% skid lining is:
TOTAL HEAT INPUT kcal/h 84,800,000
For this reason the total installed capacity is split as follows:
Burner Burner Total zone

Zone Zone
capacity capacity
name
n° type (each Mcal/h) (Mkcal/h)
1 Top Pre-heating zone 4 Lateral 2.600 10.400

MAB300
2 Bottom Pre-heating 4 Lateral 3.200 12.800
zone MAB350PP
3 Top Heating 1 zone 6 Lateral 2.600 15.600
MAB300
4 Bottom Heating 1 6 Lateral 3.200 19.200
zone MAB350
5 Top Heating 2 zone 6 Lateral 2.600 15.600
MAB300
6 Bottom Heating 2 6 Frontal 3.200 19.200
zone MAB350
7 Top Soaking zone 16 Radiant VG4 300 4.800
right side
9 Top Soaking zone left 16 Radiant VG4 300 4.800
side
8 Bottom Soaking zone 9 Frontal 1.100 9.900
MAB200 PP
TOTAL 112.300
The installed thermal capacity of the zones results higher than thermal capacity of the
furnace.
The thermal capacity distribution permits the best furnace flexibility at the different operating
conditions.
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Nitrogen purging system
Nitrogen is supplied by the customer to take-over point, at 17 bars. The pressure is then
reduced at 2000 daPa for purging the natural gas network. The reduction will be provided
by two different reducing valves working on different pressure range. (The first one will
reduce nitrogen pressure from 17 to 4 bar, the second one from 4 to 0.2 bar)
The nitrogen purging system is used to clear the pipes from gas during maintenance service.
The system is designed for purging the burners or the pipes, or eventually both. For the
purging of the burners, after shutting off the gas safety valves, automatic valves for nitrogen
close to the burners must be actuated; in such a way nitrogen purges the burner from any
residues unburnt gas. The nitrogen then escapes through the vent pipe near the burner
manifold.
For the purging of the pipe, after shutting off the gas safety valves, the system allows to
open manually the main N2 valve located close to the gas manifold. The nitrogen purges all
of the combustion gas from the pipes up to the safety valves of the pipes which depart to
each combustion zone. The escaping gases flow into the atmosphere NOT through the
furnace but through a specific tunnel communicating via a manual valve (to be opened
during this procedure) with the gas system’s pipes.
The nitrogen purging system is shown in the attached schematic Dwg. DP07XL-JC33-P7300-
FD001÷004
The nitrogen pipeline is equipped with the following main devices:

 Manual nitrogen inlet shut-off valve for main line (upstream automatic shut-off valves
for gas);
 One automatic nitrogen inlet shut-off valve for each zone (downstream automatic shut-
off valves for gas);
 Manual nitrogen outlet shut-off valve for each zone (on vent pipes);
The nitrogen distribution system will allow purging all gas pipes when a stop for maintenance
is scheduled or becomes required for safety reasons. The system will be designed to allow
the purging of a single furnace zone when required.
The nitrogen purging feeding system will be divided in several zones as follows:
 One line with manual shut off valve for the main manifold;
 One line with automatic shut off valve for each of all top and bottom zones;
Nitrogen piping will be supplied with all necessary flanges, gaskets, bolts and supports.
Instrument air system
The compressed air system is used for feeding heating system devices either for control or
for safety purposes.
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Waste gas system
Waste gases outlet and duct
The waste gas outlet is a down take type.

In fact the waste gases flow from the furnace through openings in the bottom part of the
charging wall and are draught inside an internal refractory lining duct up to the
recuperator.
Downstream the recuperator the gases flow towards the stack.
The metallic ducts are made by stiffened steel plates .
Furnace pressure control valve (Damper)
The furnace pressure regulation is obtained by means of a pneumatically driven steel

butterfly valve with air-cooled shaft installed downstream the recuperator.
Stack
The waste gases are removed from the furnace by means of a stack (natural draught) and
discharged to the atmosphere.
The stack is realized in rolled carbon steel, internally refractory lined and it is self
supporting.
- Stack height 75 m
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3 FURNACE AUXILIARY EQUIPMENTS
2.1.1 Conveyance through the furnace

During their conveyance through the furnace, at no stage will the beam blanks slide over the
beam but will move forward step by step avoiding any friction or rubbing.
The beam blanks will be gently lifted from the fixed beam by means of movable beam moved
forward and gently replaced onto the fixed beam. The position of fixed and movable beam
are defined in such a way that there is a minimum drift and minimum skewing as the beam
blanks forwarding in the furnace. The rigidity of the structure below the movable frame and
the guiding mechanism, ensure that the drift is limited. The walking beam cycle is
rectangular, i.e. the vertical and horizontal movements are never carried out simultaneously.
Lifting/Lowering and transfer movements are done with variable speeds by means of
proportional valves, in order to ensure :
 a gradual start-up and stoppage of the lifting/lowering and transfer movements,

which prevents excessive stresses on the mechanical system and guarantees a
linear conveyance of the beam blanks through the furnace avoiding damages to the
refractory insulation by vibrations,
 a relatively high speed to obtain a cycle period, compatible with the required
charging and discharging rate.
Vertical movement
Lifting and lowering of the walking beam are achieved by means of two hydraulic cylinders,
forcing the lower moving frame equipped with top and bottom wheels, to run up and down
the inclined ramps.
During these movements, the transfer cylinder is hydraulically blocked.
Horizontal movement
The transfer movement of the walking beam is also achieved by means of hydraulic
cylinders, which acts directly on the upper moving frame over the top wheels of the lower
frame. During the transfer movement, the lift cylinder is hydraulically blocked. Considering
the blooms and beam blanks schedule to be reheated, the transfer cylinders is provided with
a maximum stroke of 590 mm, but actually translation stroke is variable and function of
charge detection by photocell at discharging side
Centering devices
The lateral guiding of the frames is realized by a special mechanical centering devices
designed for continuously centering of the movables frames avoiding any lateral deviation of
the charge or stresses on the supporting wheels.
There are two centering devices at the extremity of the frame. The centering action is carry
out along the central axis of the movable frames.
The centering device include: Two vertical guides fixed on the travelling frame; Two vertical
guides anchored on the under furnace concrete base and four pair of centering wheels fixed..
on the lifting frame
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Movable Frames
The whole system will be designed for lifting and for travelling. It will be able to handle
stocks according to the charge schematic.
During the heating the frame system will move the stocks through the furnace from the
charge to the discharge end and it can, if necessary, raise and lower the stocks in the same
position during long mill delays or park the frame so that skids are at the same level (fix and
movable) for optimum support of the stocks.
The whole frame system will be designed to transport a full bed of stock having the max.
weight.
The walking movement is obtained by a set of upper and lower wheels mounted on the
lifting frame: the upper wheels ensure the horizontal movement of the travelling frame, while
the lower wheels ensure its lifting movement by a set of ramps.
 A – Travelling Frames
This system is foreseen of N°1 (one) frame.

The frame is made of large section beams rigidly stiffened together and they carry the
movable beams.
 B – Lifting Frame
This system is foreseen of N°1 (one) frame.

The frame is made of large section beams rigidly stiffened together and will carries the
upper and lower wheels for the purpose mentioned above.
Furnace Skid Arrangement
The proposed skid arrangement and the stock loading schematic designed for row charging,
is equipped with the skid arrangement mentioned at page 4.
The basic technological principles considered by Danieli Centro Combustion while proposing
this skid system are listed below:
 The system must be carefully designed in order to limit the side flexibility especially
when long vertical posts are required while keeping the size of the vertical posts as small as
possible.
 The shadow effect of the skids greatly contributes to the skid mark formation. Since it is
evident that the smaller is the section of the skid the smaller is the shadow effect, Danieli
Centro Combustion is proposing skids with rectangular cross section.
 In order to improve skid life expectancy it is essential to cool the skid with the proper
cooling system. Since plant water is normally unsuitable for a reliable operation, a close loop
cooling water system will be used. The skid system must be divided in many independent
circuits each one with its own heat loss requirement but the same ΔT and ΔP. Each circuit
must also be calculated considering the nominal flow plus the additional flow required to
compensate the loss of the lining
The skids frame in the soaking zone is designed with off-set skids and thus decrease the
skid mark effect. Skids from charging to discharging are equipped with high alloy riders.
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Skid Frames System (Water Cooled)
As previously mentioned, all skid frames are designed with a water cooled system in order
to reduce the quantities of water circuits.
In order to reduce the skid marks on the stocks, the last skid sections has been staggered.
All skid frames will be insulated by a inner layer of ceramic fibre blanket and a outer layer of
high strength castable.
The hydraulic system will control both the lift and the lower motion in slow-down (“soft
touch”) mode, in order to minimize the vertical impact forces on the skids during the stock
transfers between walking and fixed skids.
Movable skids must be positioned at the same level of the fixed skids to optimize the
support of the stocks.
 A – Fixed and movable Skid Frames

(See charging scheme DP07XL-JC33-M1455-FD002)
All fixed and movable horizontal skids are built by high thickness rectangular pipes in order
to achieve the following main advantages:
- In comparison to a circular double pipe system, the skid-mark effect will be reduced because
the shade of the rectangular pipe is less than the shade of the circular double pipe,
maintaining the same mechanical resistance.
- The number of the water cooled circuits will be reduced and the cooling plant will be
more simple.
Vertical columns are built by high thickness circular pipe in order to ensure the maximum
level of the mechanical stability on all directions.
The proposed skid arrangement and the stock loading schematic designed for single row
charging, is equipped with the following skid arrangement:
Remark: Movable and fixed skid frames will be split in several sections, the last of
which will be staggered just in correspondence of the last 25% of the furnace length.
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Furnace Lifting And Travelling Mechanisms
A set of upper and lower wheels are mounted on the lifting frame.
The running of the bottom wheels along a set of ramps, anchored on the furnace bottom
foundation, generates the lifting and the lowering of the travelling frame which is supported
on the upper wheels. This movement is achieved by two hydraulic cylinders mounted on
both the lifting frame and on the furnace bottom foundation.
The horizontal movement is achieved by two hydraulic travelling cylinders (one master, one
slave) forcing the travelling frame to run forward (or backward) on top of the upper wheel
set.
These cylinders are mounted on both the travelling frame and on the foundation.
When the vertical lifting and lowering of the travelling frame occur the travelling cylinder is
hydraulically locked.
 A – Wheels
Both lift and travel body wheels will be made in alloy steel and deep hardened on the contact
surface and they are installed on the lifting frame.
Each wheel is mounted on a high strength steel shaft which is supported by a pair of
spherical roller bearings and housing.
The bearings are lubricated through a bore in the shaft.
 B – Ramps
The sloped ramps are made of high thickness carbon steel plate and are anchored to the
furnace bottom foundation.
 C – Hydraulic Cylinders
The body of all cylinders is seamless thick wall steel tube and the rod is chrome steel plated.
Rod eyes, on both ends, are removable machined steel.
Each cylinder has a shock absorber on the front and the back.
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Hydraulic equipment
(See schematic Dwg n° 6.080787.Z)
The furnace is equipped with a hydraulic station, mainly consisting of:

N°5 main pumps (4+1 stand-by), each one with the following characteristics:
- type piston
- flow rate 360 l/min approx.
- pressure at outlet 150 bar
- RPM 1500
- power 110 kW
N°1 + 1recirculating pump with the following characteristics:
- type screw
- flow rate 700 l/min
- pressure max 5 bar
- RPM 1500
- power 15 kW
N°.1 oil tank with 7000 l capacity
N°.1 oil heat heather
N°. 5 oil filters
Valves, level and pressure indicators/switches and all other instruments are indicated on
attached hydraulic station diagram.
Valves stands control are indicated on attached relevant diagrams.
The hydraulic station has been designed, on the basis of the attached time cycle, to feed
the below listed machines:
User Cylinders data Control

Kick-off Lifting n.6x  200 / 140 stroke 110 mm ON/OFF for each
couple of cylinders
Walking Beam n.2 x  220 / 160 stroke 110 mm proportional
Translation
Walking Beam n.1 x  360 / 220 stroke 1020 mm proportional
Lifting
Kick-in lifting n.4x  200/140 stroke 110 mm ON/OFF with N°2 stages flow divider
Charging door n.1 160/100 stroke 1500 mm ON/OFF
Discharging n.2 160/100 stroke 1500 mm ON/OFF for each cylinder
door (1 for each half door)
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Charging / Discharging doors
These doors will be operated by a pneumatic cylinder and chain system, insulated with
insulating refractory castable. They are fabricated from 0.2% chromium castings.
Inspection and maintenance doors
Inspection side doors
N°6, Three on the right side and three on the left side, (320mm x 320mm) Side doors are
arranged over the entire furnace length. at the pass line level permitting the observation of
the stocks and burners flames.
These doors as well as their supports are by cast iron. and lining with refractory material
All doors are manually operated.
Inspection and cleaning doors
N°4, two on the right side and two on the left side, (500 mm X 540 mm) inspection doors are
provided at hearth level and N°1 on the pass line in front of the discharging door to permit
inspection and eventual scale cleaning.
These doors are manually operated.
Maintenance doors
For periodical maintenance, to permit access into the furnace,

N°2 opening (1550 mm X 900 mm) are provided at floor level on the side walls The
maintenance doors are closed by refractory brick.(dry & without cement) and steel covering
plate on the furnace shell)
N°2 doors are provided on the lateral wall of the down take manifold.
N°2 man holes ( 600 mm x 600 mm) are provided up stream and down stream of the
recuperator on the waste gas duct.
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Water seals
Water seals are provided upper the walking frame, to prevent cold air entering through the
openings between fixed beam.
Sealing consists of water troughs in which seal boxings are immersed.
Blades are connected to the furnace fixed frame under the sealing boxes while water
channels are connected to the movable frame.
Scale is displaced by blades in direction of the. furnace charging side by movement of the
movable frame, then scale and water are discharged thought a sloped pipe up to the mill
flushing.
Water troughs, seal blades are designed considering easy inspection and maintenance
and are made in Stainless steel plates..
Dry scale hoppers
For scale removal, 5 special hoppers are provided under the discharging roller way inside
the furnace.
Large openings are realized in the furnace hearth to collect scale falling down during the
stocks movement on the roller ways.
Scale is collected in vertical hoppers closed in the lower part in order to avoid cold air inlet
inside the furnace in order to remove in easy mode the scale into the hopper it is foreseen
one lateral opening from which a bar can be inserted through.
Each hopper is provided with a pneumatic door .with counter weight.
Scale is removed by opening scale doors and utilising a portable trolley.
Charging Roller Way (outside the furnace), Bloom Centering
Bloom/Beam Blank are centered according to the charging scheme (see Dwg DP07XL-JC33-
M1100-FD011) and will be verified by means of a laser device located behind the roller ways.
After measuring, the stock enters inside the furnace through frontal door opening, by means
of the charging roller way equipped with N°11 rolls, water cooled and a kick in machine.
Kick-in machine
In order to have flexible charging of beam blanks and blooms from the roller way on the
fixed beams inside the furnace, a kick-in machine is provided. This machine puts the charge
in the right position, ready to be lifted and positioned on the first useful position ont he
beams inside the furnace. Machine translation is actuated by gearmotors, arm lifting is
actuated by hydraulic cylinders.
Kick-in translation is actuated by gearmotors, arm lifting is actuated by hydraulic cylinders.
____________________________________________________________________________________________________________
Kick-off machine
After heating up at rolling temperature, the kick-off machine discharge, one by one, the
beam blanks and blooms on the discharge roller way inside the furnace.
The kick-off is a two-halves car type machine in order to have the best flexibility
discharging the beam blanks from the furnace.
In case of double row charging, one row at a time will be discharged by means of half car.
Laser measuring system is provided on discharging roller way, to detect the distance
between the beam blank to be discharged and the roller way.
Discharging roller way
A discharging roller way is foreseen to transfer the stocks out of the furnace. The roller way
is equipped with N°13 rolls, water cooled, driven by VVVF converter, that shift the stock at
the furnace exit side.
Closed loop cooling water system
The water system feeds all parts to be cooled like kick-off holes, kick-off fingers, the
stopper device, the charging and discharging rolls, the fixed and mobile beams,
pyrometers, T.V.C.C. device, the photocells, the hydraulic unit, etc. (see Dwg. DP07XL-
JC33-P7100-FD001÷004)
4 UTILITIES
See attached document in revision 03. (Utility List)
____________________________________________________________________________________________________________
5 REFRACTORY AND INSULATION
In order to protect personnel, reduce thermal losses, and provide structural integrity of the
furnace shell, various refractory materials are used in the construction of the furnace.
The following features have been taken into account for selection of refractory materials:
- operational conditions
- working temperature
- service duty (scale and abrasion resistance)
- insulating quality
- durability
- maintainability
- installation procedure
Refractory specification
DESCRIPTION THICKNESS TYPE

(mm)
ROOF DISCHARGING SIDE See supplier technical documentation
- Plastic castable 63% Al2O3 180
- Ceramic fiber 46% Al2O3 40
- Light weight insul. castable 28% Al2O3 80
ROOF CHARGING SIDE See supplier technical documentation
- Medium weight insulating castable 49% Al2O3 180
- Light weight insul. castable 28% Al2O3 120
WALLS SIDE- BURNERS ZONE See supplier technical documentation

- Plastic castable 63% Al2O3 230
- Insultating bricks 40% Al2O3 115
- Calcium silicate board 75
WALLS-RECUPERATIVE ZONE See supplier technical documentation
- Medium weight castable 49% Al2O3 230
- Insulating bricks 40% Al2O3 115
SKIDS See supplier technical documentation
Tixotropic castable 66% Al2O3 45
Insulating fibre 15
HEARTH CHARGING SIDE See supplier technical documentation
- Refractory castable 46% Al2O3 130
- Insulating castable 31% Al2O3 180
HEARTH DISCHARGING SIDE See supplier technical documentation
- Refractory castable 61% Al2O3 130
HEARTH – SCALE CHUTE DISCHARGING ZONE See supplier technical documentation
- Refractory castable 63% Al2O3 125-350
- Insulating bricks 40% Al2O3 125-125
____________________________________________________________________________________________________________
CHARGING WALLS See supplier technical documentation

- Insulating bricks 40% Al2O3 115
DISCHARGING WALLS See supplier technical documentation

- - Plastic castable 63% Al2O3 230
- Insultating bricks 40% Al2O3 115
WASTE GAS DUCT UPSTREAM REKU AND REKU See supplier technical documentation
- Insulating Castable 29% Al2O3 125
WASTE GAS DUCT DOWNSTREAM REKU See supplier technical documentation

- Light weight Castable 29% Al2O3 150
WASTE GAS DUCT STACK See supplier technical documentation

WASTE GAS FLUES DAMPER See supplier technical documentation

- refractory castable 50% Al2O3 150
____________________________________________________________________________________________________________

Furnance Surface

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 DANIELI CENTRO COMBUSTION CHAPTER 1

Customer and plant location EMIRATES STEEL INDUSTRIES

Commissioning year 2011

see drawing DP07XL-JC33-M1100-FD001 LAYOUT – PLAN VIEW

Roll to roll external length 39,975 mm

Product Bloom and beam blanks

- materials Low carbon Steel, Medium carbon Steel, Low alloy

Type Unit Bloom BB1 BB2 BB3 BB4 BB5

- reference charge 460 x 1050 x 12,000 mm

(See also dwg:

- DP07XL-JC33-M1100-FD011 Charging Scheme-Plan View;

- DP07XL-JC33-M1100-FD012 Charging Scheme-Longitudinal view

The specific heat consumption

Plant configuration - Furnace configuration

The plant configuration is:

. charging frontal, on external roller way and charging machine

The heating system is composed by:

See below for detailed description of equipment

Combustion control : PLC regulation with Level 1 supervision; Level 2 optimisation

The heating system is shown on the following schematics:

- Combustion air manifold see dwg. DP07XL-JC33-P7400-FD001

2.1.1 Combustion air system

Combustion air fan: See dwg. DP07XL-JC33-M1468-FD002

The main features of the fans are the following:

Flow rate Nm3/h 120,000

Pilot Air Fan

The main features of the fans are the following:

Flow rate Nm3/h 500

The recuperator is counter flow type.

The recuperator is protected against combustion air overheating by means of a bleeding

Item Data Unit Case A Case B Case C …

Geometric features and speed

Materials: rows numbered acc. to waste gas direction

Thermal capacity of the zones

- Different dropout temperatures,

TOTAL HEAT INPUT kcal/h 84,800,000

For this reason the total installed capacity is split as follows:

Burner Burner Total zone

1 Top Pre-heating zone 4 Lateral 2.600 10.400

Nitrogen purging system

The nitrogen pipeline is equipped with the following main devices:

Instrument air system

Waste gas system

Waste gases outlet and duct

The waste gas outlet is a down take type.

Furnace pressure control valve (Damper)

The furnace pressure regulation is obtained by means of a pneumatically driven steel

3 FURNACE AUXILIARY EQUIPMENTS

2.1.1 Conveyance through the furnace

 a gradual start-up and stoppage of the lifting/lowering and transfer movements,

This system is foreseen of N°1 (one) frame.

This system is foreseen of N°1 (one) frame.

Furnace Skid Arrangement

Skid Frames System (Water Cooled)

 A – Fixed and movable Skid Frames

Furnace Lifting And Travelling Mechanisms

The furnace is equipped with a hydraulic station, mainly consisting of:

User Cylinders data Control

Charging / Discharging doors

Inspection and maintenance doors

Inspection side doors

Inspection and cleaning doors

For periodical maintenance, to permit access into the furnace,