EMG-21 express multicomponent gas-analyzer

Main technical parameters

Special gas-analyzing complex based on EMG-21 express multicomponent gas analyzer is developed to solve tasks of technological modes automatic control development, lowering of emergency situations, monitoring of industrial outbursts of industrial fixtures in ferrous and non-ferrous metallurgy, oil chemistry, coke chemistry, coal industry, fuel and energy industries.

Our gas-analyzing devices are utilized in converter and blast-furnace processes and in melting divisions of the following metallurgical complexes from 1993:

• in converter and blast-furnace processes
  JSC "ISPAT KARMET" (Temirtau) - 4 complexes;
• in converter processes
  JSC "NLMK" (Lipetsk) - 2 complexes;
• in converter and blast-furnace processes
  JSC "MMK" (Magnitogorsk) - 8 complexes;
• in converter processes and in oxygen production
  JSC "Severstal" (Cherepovets) - 4 complexes;
• in autogeneric production and for ecological monitoring
  JSC "GMK "Norilsky nickel"" - 3 compexes;

Currently our gas-analyzing complexes are being installed at the steel vacuuming fixture (JSC "Severstal", JSC "MMK"), shaft furnace by FUCHS (JSC "Severstal"), tubular furnaces (JSC "Severonickel", JSC "GMK "Norilsky nickel""), thermoelectric plants (JSC "Severstal", JSC "GMK "Norilsky nickel""), catalyzing fixtures of oil and petroleum processing (PO "Kirishinefteorgsyntez", JSC "Slavneft-Yaroslafnefteorgsyntez"), natural gas liquation and processing fixtures (P. "Lentransgas" JSC "Gasprom").

Industrial outbursts monitoring and development of database for technical norms estimation in accordance with the specific indicators with the use of gas-analyzing systems by METTEK is being performed for JSC "GMK "Norilsky nickel"" (Norilsk, Monchegorsk).

Our equipment also can be effectively used for the technological processes control and safety provision at the field of development and processing of coal, shales, oil gases, gas-condencate, biogas as well as at the field of pure gases production.

EMG-21 gas-analyzers are kitted with continuos gas-sampling systems, systems of analyzed gas output purification, technical and technological gases input by heated impulse lines developed and designed by METTEK.

The basic gas analyzing complex:

• EMG-21 gas-analyzer equipped with the industrial running controller.
• Heated impulse lines of fluorineplast (up to 3 parallel gas channels).
• Heat-resistant gas sampling probes (up to 1500C^o).
• Gas-sampling and sample-preparation systems equipped with microprocessor control block and electronic mnemonic scheme.
• Graphical station installed at the technological control panel of the device.
• Computer-lock providing adjustment with external local networks.

Such complex performs the following operations:

• Continuos gas-sampling and gas probes transportation.
• Dirt purification, gas-sample cooling and condencate removing.
• Commutation of gas lines from several (up to 24) different sample points.
• Gas-sample provision to the mass-analyzer for the volume percent composition estimation.
• Full diagnostics of the complex with the results indication at the mnemonic scheme and control computer station.
• Carrying the data on gas-phase composition to the technological department and to the automatic control station.
• Archiving.

Converter processes.

Continuous gas-mixture composition analysis of converter gases at the gas-output tract and at the fire-tube, of oxygen-blast and of gas in argon-blast mode provides the lowering of workshops power consumption and explosion characteristics of gas-tubes and make the efficiency and produced steel quality higher.

The installation of such complexes turns to be economically reasonable because of:

• possibility of full-combustion melting;
• reducing of re-blasts and double blasts;
• shortening of average time of melting process within one shift;
• steel quality improvement;
• reducing of blast oxygen and other technological materials (lime, cocks) usage.

EMG-21 gas-analyzer ensures exact determination of CO and CO₂ up to 0,05%. This provides forecasting of steel production by carbon with the accuracy of 0,01% for lowly alloyed steels and with the accuracy of 0,05% for middle alloyed steels.

The scheme of gas-analyzing complex for converter processes

The data measured and processed by gas-analyzing complex provides the following possibilities for the operator at the converter control station:

• To determine the exact moment of meting "combustion".
• To determine the exact moment of blast-finish by CO falling-down curve.
• To control the level of lime assimilation.
• To control the hermetic characteristics of gas-output tract in accordance with the O₂ chart.

Graph of archive a swimming trunks

For the first time EMG-20 gas analyzers were setup at the oxygen-converter workshop of Magnitogorsk metallurgical complex in 1996. Operate reliability of the equipment and high level of servicing were the main reasons of our long-term co-operation. Nowadays Magnitogorsk metallurgical complex has become our regular customer. Currently 8 gas-analyzing complexes by METTEK are working at the converter and blast furnace workshops of the plant. One of our important activities at the field is automation of the workshops at metallurgical industrial plants. The 3-d converter of Magnitogorsk metallurgical complex implemented in 1999 is a good example of such work. The 3-d automatic converter workshop is considered to be nowadays the most modern in CIS; it is able to perform 70-80 melting within 24 hours in accordance with the international quality standards requirements.

One of the most important units of automatic control system of the workshop is an informative control system based on EMG gas analyzing complexes. The system provides:

• establishment of information environment needed for the melting process performance and for optimal technological modes choosing
• establishment of database needed for assessments estimation and for basic technological parameters forecasting during melting process (residual carbon in steel, temperature, etc.)
• melting technology control
• archiving of technological processes for every melting and development of melting passports needed for the analysis of accidents and technological modes violation reasons

Blast-furnace processes.

The use of gas-analysis in blast-furnace processes helps in resolving tasks of emergency situations reduction, technological modes control and optimal technological parameters adjustment. Such improvements provide reduction of blast oxygen, natural gas and coke consumption rates, makes labor efficiency and quality of produced pig iron higher.

EMG-21 gas-analyzing complex ensures operative gas-composition control all along the blast-furnace radius in real time taking gas samples with the use of movable sondes.

The data on blast-furnace top gas serves for:

• process uniformity control in ore melting
• reducing medium control in blast furnace mouth
• caloric value of blast-furnace top gas and natural gas determination

The scheme of gas-analyzing complex for blast-furnace processes

Graph of sharing the gases on radius of blast furnace

The implementation of gas-analyzing complex by METTEK in blast-furnace processes at the plant of JSC "ISPAT KARMET" (Temirtau, Kazahstan) resulted in ore purchasing control and rational resources consumption.

Autogeneric processes

Continuous gas-analysis on-line ensures unit's heat balance maintenance in operating mode, autogeneric melting mode control, accident prevention and industrial safety increase.

The scheme of gas-analyzing complex at the fixture of autogeneric melting

Implementation of gas-analyzing complex at autogeneric melting unit provides:

• burner / melting mode control in accordance with percent composition of SO₂, CO₂, O₂
• oxidizing melting of concentrate and slag output preparation mode (reducing mode) control
• waste gases SO₂ concentration control for sulphuric acid production

Graph from archive of autogeneric melting unit

Autogeneric processes gas-analysis performed at AO "Severonickel complex" (Monchegorsk) eliminates the "unit foaming" process.

Oil chemistry industry

The use of gas-analysis in petroleum industry provides:

• hydric reducing gas composition and waste gases control for processing units in catalytic oil processing (reforming, cracking etc.); technological process optimization and high quality of products produced
• inert gas and air input regulation during catalyst regeneration process needed for quality improvement of expensive catalyst reduction
• oxygen complete combustion and CO₂ (destroys catalyst) absence control in inert gas production

The scheme of gas-analyzing complex for the control of oil reforming processes

During 2000 METTEK in co-operation with the Department of Oil- and Coal-chemistry Technologies of St-Petersburg Technological Institute was making estimations of gaseous phase of different units at NZP "KINEF" plant (Kirishi, Leningradskaya obl.). Estimations, analyzing of the results and control measurements performed have shown the practicability of EMG-21 implementation, especially for technological processes optimization at the following units:

1. at the electric demineralizing plant using atmospheric and vacuum pipe-steel - to perform express analysis of low-boiling fractions composition and to perform percent fraction composition estimation and product purification control
2. at 62-105C, 105-127C, 85-180C low-boiling fractions catalytic reforming units - to perform feedstock express analysis and control, to perform catalytic reforming and final product purification control
3. at 135-240C fraction hydro fining units - to perform express composition analysis and quality control of hydrogen input, to perform H₂C, NH₃, H₂O output and fraction desulphatesation control
4. at 190-360C fraction hydro fining units - to perform hydro fining control
5. at catalytic reforming units during catalyst regeneration - to perform regenerative mixture express analysis, to perform CO₂ content and gas mixture control at the technological line

Sequential automatic scan of different gas-sampling points and possibility of simultaneous analysis of different technological gases resulted in high efficiency of EMG-21 mass-spectral complex utilization for running and control of technological processes. The complex performs both organic and inorganic compounds analysis for one and the same gas mixture.

Thermoelectric plants

The use of a special gas-analyzing complex at thermoelectric plants of different types provides:

• Percent estimation of gas output from furnaces of thermoelectric plants.
• Percent estimation of natural gas estimation.
• Determination of specific combustion heat of coalo, fuel oil and natural gas.
• Determination of efficiency, air surplus coefficient and heat loss of gas output.
• Optimization of operation mode of boiler units (to choose the optimal proportion fuel and air input).
• Control and lowering of pollution substances outbursts to the environment.

The scheme of gas-analyzing complex for thermoelectric plants of different types