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Similar to Continuous Casting Forum-2015 - Copy (2)
Similar to Continuous Casting Forum-2015 - Copy (2) (20)
Continuous Casting Forum-2015 - Copy (2)
- 1. Continuous Cast Coolant Filtration and Caster Water Filtration Presented By Tom Horn and Mohammed Al-Bedour Filtertech, Inc. USA Global Continuous Casting Forum Atlanta GA. April 2015
- 2. • Filtration system concepts • Coolant temperature management • Different filter types
- 3. Important Filtration Questions • Flow rate? (for entire system sizing) • Pressure required? (for pump sizing) • Heat to be removed? (heat exchange) • Available cooling water? (cooling tower) • Type of coolant to be used? • Single or split mill coolant systems?
- 4. System Sizing Factors • Filter size in gpm/sq ft (roughing/finish) • Tank volume (20 min. ideal 10 minimum) • Pump size and type
- 5. Gravity Flow to the Filter Heat Exchanger Clean Supply PumpRecirculation Section Clean Compartment Recirculation Pump Filter Rod Mill
- 6. Gravity Flow Into Flatbed Air Vacuum Filter 20 MT/Hr SCR Mill With CLI Feature and Re-Circulated Filtration
- 7. Drain by Gravity to Self-Cleaning Conveyor Tank, Pump to Filter Heat Exchanger Filter Feed PumpClean Supply Pump Filter Rod Mill Conveyorized Tank
- 8. 1000 GPM (3800 LPM) System with Conveyor Tank & Flat Bed Vacuum Filters
- 9. Split System Concept for Roughing & Finishing Mills Finishing Mill Heat Exchanger Filter Clean Supply Pump Re-circulation Feed Pump Reservoir Tank Roughing Mill Clean Supply Pump Filter Conveyorized Tank Heat Exchanger Filter Feed Pump
- 10. Flatbed Air Vacuum Filters For Roughing Mill 50 MT/Hr
- 11. Flatbed Air Vacuum Filter For Finish Stands 50 MT/HR
- 12. Coolant Filtration for Continuous Cast Aluminum Rod • Concepts and Components (Same as copper) • Air Vacuum with Lower GPM/ft² (LPM/m²) allows more filter area for the application • Higher Coolant Concentration • Higher Operating Temperature
- 13. Coolant Temperature Management Coolant temperature management includes both system heat removal and heat addition to enhance coolant and rolling mill performance.
- 14. Process Heat Removal Temperature Sensor Controller 105 F To Process Clean Supply Pump Cooling Water In Out Heat Exchanger Plate and frame heat exchangers precisely remove the process heat from the coolant controlling the temperature with cooling water System Tank
- 15. Electric Immersion Heater Temperature Sensor Heat Addition Temperature controller 85 F Includes a tank heater or heaters that keeps the coolant warm during process down times to avoid cold production start-up . System Tank
- 16. New Heating Loop System Design Temperature Sensor Controller 90 F To Process Clean Supply Pump Cooling Water Natural Gas Heater Heat Exchanger Coolant Circulation Pump Hot Water Pump Hot Water Loop 90 F Optimal Start-up Temperature Heat removal Heat addition
- 17. Heating Loop Detail System Tank Temperature Sensor Temperature Controller 90 F Natural Gas Heater (Boiler) Coolant Circulation Pump Hot Water Pump TI PI TI PI TI PI TI PI PI Pressure Relief Valve Condensate to drain Expansion Tank Make-Up Water Inlet
- 18. Factors In Sizing • Warm-up time • Tank volume • Required btu’s • Hot water flow rate • Coolant flow rate
- 19. Completed Skid
- 20. Benefits to Temperature Management with Heating Loop Design • Significant Reduction of large “cobbles” • Improved tank temperature distribution • No hot spots due to heater contact • Lower energy cost by maintaining warm • Higher production rates due to less down-time • Extended coolant life with consistent temperatures
- 21. • Flatbed Air Vacuum Filter Filter Types • Liquid Vacuum Filter • Deep Bed Gravity Filter • Band Filter
- 22. Air Vacuum and Liquid Vacuum Comparison VS
- 23. Dirty Inlet Header Overflow Weirs Air Vacuum Producer Disposable Filter Media Media Drive End of Media Switch Vacuum Chamber Clean OutletCarrier Belt Spent Media Re-winder/Sludge Separator Tramp Oil Skimming Trough Air Vacuum Filter •High differential pressure is developed below the liquid pool by the vacuum producer, and is independent of process.
- 24. Liquid Vacuum Filter Clean Supply Pump Filter Media Spent MediaDirty Compartment Vacuum Chamber Pneumatic Vacuum Break Clean Compartment Dirty Inlet • The vacuum pressure is created by the pump suction and filtration is dependent on the pump
- 25. Unique Design Features • Efficient side seals • Controlled Level lndexing feature ( CLI )
- 26. Air Vacuum Filter Side Seal Design Stainless Seal Spring Teflon® Stationary Seal Moving Seal Filter Media Flatwire Belt Belt Support Roller Coolant Pool
- 27. Positive Side Seals (No Migration)
- 28. Controlled Level Indexing (CLI) • The consistent vacuum produces a uniform pressure drop across the filter media. • And a highly efficient filter cake removes more fines that means cleaner coolant. Solids migration is minimized as the media very slowly enters the filter Constant Coolant Level is produced
- 29. • The consistent vacuum also means lower power consumption. • Media usage will decrease due to efficient and uniform cake Controlled Level Indexing (CLI)
- 30. Liquid Vacuum Filter Clean Supply Pump Filter Media Spent Media Dirty Compartment Vacuum Chamber Pneumatic Vacuum Break Clean Compartment Dirty Inlet • No positive side seals • Long index cycle of media causes solids migration
- 31. A Liquid vacuum filter has no side sealing and the discharge is very wet copper oxides
- 32. Flat Bed Air Vacuum Filter with Media Re-winder and Separator
- 33. Gravity Filters • Band Filters • Deep bed filters • Gravity with vacuum drying option
- 34. Band Filter No seals and no pool depth resulting in poor filter cake production
- 35. Band Filter Light duty construction does not meet mill high standards
- 37. Deep Bed Gravity Filter With Extended Ramp & Drying Filter Media Flat Wire Belt Conveyor Dirty Inlet Header Optional Sludge Dewatering & Drying Unit Extended Drying Ramp Clean OutletDirty Overflow Deep Bed Liquid Pool
- 38. Having the best system possible: • Producing higher rates • High quality rod • Less Maintenance • Increased roll life • Extended coolant life
- 39. Thank you References The Joe Scalise technical paper Continuous Cast and Caster Water Filtration Concepts Gary Spence feed back on heating loop system