PR OC ESS TEC HNOLOGY INTERNATI ONAL

EAF JetBOx™ Combustion System

OPERATION MANUAL

PR
NOTICE:

The information contained in this manual is proprietary to Process Technology International, Inc. and may not be reproduced in whole
or in part on any media whatsoever without the express written consent of Process Technology International, Inc.

The safe operation of this equipment depends on proper training of operators and careful maintenance of the equipment. Under no
circumstances should this equipment be operated by personnel who are not trained in operating this equipment and are not aware of
the danger of improper control. If not properly operated, there is a danger of fire and explosion. Regular maintenance by qualified
personnel must ensure safe operation.

 Process Technology International

1940 Forge St • Tucker GA 30084-6608
Phone 770 934-9502 • Fax 770 414-9037
PTI Operation and Safety Manual Page 1
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 PROCESS TECHNOLO GY INTERNATIONAL

EAF JetBOx™ Combustion System

OPERATION MANUAL

PR
NOTICE:

The information contained in this manual is proprietary to Process Technology International, Inc. and may not be reproduced in whole
or in part on any media whatsoever without the express written consent of Process Technology International, Inc.

The safe operation of this equipment depends on proper training of operators and careful maintenance of the equipment. Under no
circumstances should this equipment be operated by personnel who are not trained in operating this equipment and are not aware of
the danger of improper control. If not properly operated, there is a danger of fire and explosion. Regular maintenance by qualified
personnel must ensure safe operation.

 Process Technology International

1940 Forge St • Tucker GA 30084-6608
Phone 770 934-9502 • Fax 770 414-9037

PTI Operation and Safety Manual Page 2

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 -TABLE OF CONTENTS
1.0 Introduction………………………………………………………….………………4
1.1 Chemical Energy Overview.…………...………...……………..……………...4
1.2 JetBOx Background……………………...……………………..……………...5
2.0 Equipment…………………….………………………………………………..…….7
2.1 Burners………………………………………………………………..………..7
2.2 Fuel and Oxygen Flow Control Train……………………………………….....7
2.3 Operating Control system…………………………………………………..….8
2.4 Operator Interface………………………………………………………..…….8
3.0 Using Oxy-Fuel Burners……….........................………………………………….9
4.0 Oxy-Fuel Burner Use…………………………………………………………….…9
4.1 Chemical Energy…………………………………………………………….....9
4.2 Burner Efficiency…………………………………………...……………..….10
4.3 Types of Burners……………………………………………………………...11
4.4 Carbon Injection Ports………………………………………………………..11
4.5 Burner Operating Modes…………………………………………………...…11
Burner Operating Modes………………………………………………………….13
5.0 Installation Considerations………………………………………….………...….14
5.1 Refractory Installation……………………………………………………...…14
5.2Mechanical Installation……………………………………………………..…15
5.3 Water System considerations............................................................................15
5.4 Oxygen System Considerations.........................................................................16
6.0 General Burner Safety Considerations…………………………………....…....16
6.1 Water……………………………………………………………………….....16
Water Response Procedure………………………………………………………..17
6.2 Lighting Burner………………………………………………………….…....18
Procedure for manual Lighting of Burners..…………………………………..20
6.3 Lockout………………………………………………………………….….....21
6.4 Emergency Stop…………………………………………………………..…..21
6.5 Valves…………………………………………………………………………20
PTI System Hold Fire Adjustment (for both oxygen and gas valves)………..21
6.6 Oxygen Safety…………………………………...…………………………....22
6.7 Natural Gas/LPG Safety…………………………………………………........22

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 6.8 Flash Back Control……………………………………………………….…...22
7.0 Operating Procedures……………………………………………………………..23
7.1 Start up…………………………………………………...……………….......23
7.2 Shut Down………………………………………………………………...…..24
8.0 Troubleshooting Guide……………………………………………………….…...25
9.0 HMI Guide……………………………………………………….….………………27
9.1 System Auto Mode .……………………………………...……………….......28
9.2 Manual Mode ..…………………………………………………………...…..29
9.3 Individual Burner Controls ..……………………………………………...…..30
9.4 Auto and Manual Set Up ………………………………………………...…...32
9.5 Burner Set Point and Present Values ..…………………………………...…..34
9.6 Heat Consumption and Charge Control ..………………………………...…..35
9.7 Alarms and Reset ………………………………………………………...…..36
10.0 Preventive Maintenance Matrix...............................................................................37
11.0 Instrument Air Quality Requirements.....................................................................39
12.0 Cooling Water Quality Requirements......................................................................39

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1.0 Introduction

1.1 Energy Overview

The amount of chemical energy typically represents 25 to 35% of total energy

consumption in EAF. Another important factor is that the method of chemical energy
application significantly influences electrical arc heat transfer efficiency (i.e. quality of
slag foaming, arcs stability etc).
Chemical energy consists of two main sources:

• fossil fuels supplied via oxygen – fuel burners

• lanced oxygen and carbon

Over the past three decades the average consumption of oxygen in (EAFs) has steadily
increased, and the forecast is for this consumption to continue to rise.

Over the same period of time average transformer power has increased and tap-to-tap
times have dropped considerably. This reduces the time available for efficient oxygen

50
40
O2 Nm3/tonne

30
20

10
0
1970 1980 1990 2000 2010 2020
Year

introduction and places higher demands on the new chemical energy system and its
operation. Significantly larger amounts of oxygen need to be injected per unit time. This
in turn increases the necessity of introducing the oxygen in an efficient manner.

These requirements have led to much recent advancement in the area of chemical energy
systems, and the patented JetBOxTM technology, developed by PTI, has been proven to
meet this need for increased chemical energy intensity while maximizing efficiency and
reliability.

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1.2 JetBOx Background

In order to explain how The JetBOx technology works it is important to understand two
key elements of its design. The first part of the technology is a combined burner / lance
(PTI Jet burner) which has been proven in over 30 EAF’s since 1995. The second part is
the water-cooled copper box that enables the burner/lance to be safely positioned in the
optimum position.
The PTI Jet burner can work in three basic operating modes: burner, soft lance and
supersonic shrouded oxygen lance.

It is well known that using of shrouding flame around supersonic oxygen stream
significantly prolongs jet coherency. However, the fundamental laws of physics state that
the oxygen speed and its ability to penetrate a liquid bath reduce with distance from the
burner tip, even if shrouding flame is applied. Therefore, it is desirable to reduce distance
from nozzle to liquid bath, which the oxygen has to travel, while keeping a good angle of
penetration. The same logic applies to carbon injection – to obtain high carbon efficiency
it is necessary to inject carbon close to the bath and with relatively steep angle. To
achieve this philosophy the second part of JetBOx technology is used – the water cooled
copper box, the JetBOx. Figure no. 2 shows the principal of its operation.

Figure 2 – JetBOx principal

Burner/ Soft
Lance/ Supersonic
Oxygen Jet

Carbon Stream

The copper box is designed for long life, with the ability to withstand the impact of
falling scrap, while at the same time provide excellent cooling. The box is located
just above the last course of refractory brick with the front face about in line with
the hot face of the brick. This location provides the following advantages:

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 • The burner/lance device is located low in the furnace, which promotes better heat
transfer to the scrap while the burner is in the scrap-melting mode.

• The angle is such that splash from the electrodes or from scrap charging will not
block the gas and oxygen orifices inside the combustion chamber (less plugging).

• Supersonic oxygen efficiency is maximized due to the oxy-fuel flame shrouding

combined with relatively short jet length and the ability to use the optimal jet
attack angle.

• Efficient oxygen use means less electrode oxidation.

• Refractory problems in the jet/bath area are minimized since a) the reaction zone
is relatively far away from the brick face and b) additional refractory cooling by
water-cooled copper box directly contacted with refractory.

• Injection carbon is applied close to the bath, parallel with the flame/jet, which
promotes a better foamy slag and minimizes carbon loss. It also provides the best
re-carburization of steel, if required.

• The oxidation of iron to the slag is minimized due to the better bath stirring
produced by the jets, and the ability to employ several reaction sites.

• Scrap melting; post combustion and decarburization can be accomplished with the
door closed most of the time, which yields significant energy savings.

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2.0 Equipment

PTI’s combustion system for the EAF consists of four main parts:

2.1 Burners

PTI’s oxy-fuel burner has been designed to meet the unique EAF conditions and
requirements. The burner’s water cooled combustion chamber is designed to
support flame ignition and control the mixing of fuel and oxygen inside of the
burner body which creates positive pressure inside the combustion chambers. As
well, this design has been proven to minimize plugging of the burner’s
nozzle from splashing slag.

All PTI burners have shrouded supersonic oxygen nozzles that can supply
oxygen at 1.8 – 2.0 Mach number when the burners operate in the lancing mode
and “soft” oxygen for CO post-combustion. These features provide the following
advantages during operation:

• Minimized overheating of cooling panels adjacent to the burner by

eliminating flame flash back

• Improved heat transfer into the scrap by better control of the combustion
volume

• Improved prevention and removal of build-up deposits accumulated inside

the combustion chamber

• Aid in post-combustion inside the EAF shell during the entire steelmaking
process

• Efficient assistance to the foamy slag practice

2.2 Fuel and Oxygen Flow Control Train

The flow control train is designed to provide individual control of natural gas and
oxygen flows to each burner. Carefully selected valves and instrumentation
typically do not require any maintenance during operation after the initial startup.
The train is equipped with the entire necessary safety feature including automatic
shut-off valves, double blocking valves, bleed line, and high and low pressure
switches. Easy access to any part of the train will guarantee fast service of the
system in the event of necessary maintenance or troubleshooting.

2.3 Operating Control System

Integrated operating control system is designed to provide reliable control of the

combustion system during the steel melting operation. A P.L.C. (Programmable
Logic Controller) is used to provide all changes of flows in accordance with
furnace power profile. The operational program could have several different
profiles depending on the different scrap composition, grades of steel and other
variables in the melting process. The control system also provides diagnostic of

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 a failure, alarms and warning signals, and a description of the nature of the
failure.

2.4 Operator Interface (called the HMI “Human machine Interface”)

The operator interface allows the operators to initiate burner functions, melting
programs, and access information screens. The operator can use the HMI to stop
and start the system or individual burners. In addition to the operation of the
burners, typically there are information screens that indicate permissive
functions, valve train pressures and flows, water temperature of the burners and
the JetBOx, and individual burner control.

The HMI also allows management to access the firing program by way of a
password-restricted program, as well as set points for carbon injection, and high
temperature settings.

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3.0 Reasons for Using Oxy-Fuel Burners

• High productivity furnaces need the ability to back charge as soon as

possible. Oxy-fuel burners are strategically placed in cold spots to ensure
uniform melting thus ensuring an early backcharge.

• Provides an inexpensive way to increase productivity (e.g... reduce tap to tap

times) capital cost of a new burner system is significantly lower than a new
transformer.

• Depending on cost of electrical energy the additional energy input from

burners can provide a less expensive source of chemical energy.

• Burners can be operated in such a way to post-combust carbon monoxide and

achieve benefit from additional energy release by oxidizing carbon monoxide
inside the furnace shell. This also maximizes the utilization of any fuels
found in the scrap (i.e. oils, plastics, and organics).

• Recent advances in burner technology allow decarburization of the metal

bath early into the refining stage thus, making the tap to tap time shorter.

• The ability to meter oxygen into the arc furnace allows the operator to use
more organic fuels (coke/coal) in the scrap charge than would normally be
possible.

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4.0 Oxy-Fuel Burner Use

4.1 Chemical Energy

Oxygen and natural gas when mixed in a ratio of 2:1 (called Stochiometric) at a
flow rate of 1000 cubic ft. per hour (scfh) will produce approximately one
million BTU (British thermal units) or 1055 megajoules.

26.8 Nm3/hr 53.6 Nm3/hr = 1055 megajoules = 0.3Mw

1000 scfh + 2000 scfh = 1 million = 0.3

Gas oxygen BTU MWH

The burners can also be fired with excess of oxygen to promote the following
reactions:

• C + O > CO (-)
(Carbon + oxygen produce carbon monoxide + energy)

• CO + O > CO2 (-)

(Carbon monoxide + oxygen produce carbon dioxide + energy)

• Fe + O > FeO (-)

(Iron + oxygen produce iron dioxide + energy)

Carbon sources come from charge carbon, organics in the scrap and carbon in the
scrap. The iron is the scrap. Too much oxidation of iron can become expensive
since it reduces the yield. (i.e. % of hot metal produced from the scrap charged is
approximately 90 to 92%).

4.2 Burner Efficiency

The efficiency of an oxy-fuel burner is defined as the percentage of available

energy transferred to the scrap. The remainder does not do useful work and can
overheat the water-cooled sidewalls, roof and bathhouse.

The factors affecting efficiency are:

• The amount of scrap that the burner impinges on. As the scrap in the furnace
melts down, and the burner produces a melted hole in front of it, the heat
transfer is reduced.

• Very dense scrap has less surface area; hence the flame has less surface area
to transfer heat to.

• Scrap mixes that do not have sufficient small light scrap (e.g. shredded,
bushing) to form an insulating barrier on to of the charge allows heat to be
transferred out of the furnace.

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4.3 Types of Burners

PTI produces burners/injectors that are specific to your application. Typically the
oxy-fuel capacity is 4.5 MW for sidewall and JetBOx burners and 3 MW for
EBT sump burners. The pure oxy-fuel burners produce a flame of about 5000° F
(2760 Celsius). This melts scrap by convection and radiant heat.

The oxy-fuel/supersonic oxygen burner allows shrouded oxygen to be delivered

to the flame at Mach 2 velocity (twice the speed of sound). The supersonic
oxygen capacities are normally 850, 1200, 1500, and 2200 scfm (23, 32, 40, and
59 Nm3/minute).

4.4 Carbon Injection Ports

Each JetBOx will allow the injection of foamy slag carbon as close to the slag/metal
interface as possible. This is accomplished by the patented JetBOx design, which allows
the carbon injection point to be in line with the hot face of the refractory and only two to
three inches (50-75 mm) above the last course of refractory brick. Carbon is injected by
means of a standard carbon steel pipe inserted through a water-cooled orifice. This
typically places the injection point about 18-24 inches (450- 600 mm) above the hot
metal line.
This gives the following advantages:

• Carbon efficiency is excellent since the injection point is normally in the foamy
slag.
• Carbon trajectory that is parallel to the jet/flame insures carbon is carried deep into
the slag/metal interface without disturbing the supersonic jet.
• The proximity of the carbon to the oxidizing shrouding flame promotes excellent
evolution of carbon monoxide, which in turn enhances the slag foaming.
• The carbon is driven deep into the slag, where it reacts with iron oxide to maximize
metallic yield, since it promotes conditions closer to equilibrium.
The efficient reduction reaction limits the slag temperature to optimize slag
foaming. This is especially important since JetBOx locations in the furnace
without carbon injection temp to superheat the slag due to efficient post
combustion of carbon monoxide in the slag (as opposed to over it).

4.5 Burner Operating Modes

The burners may be operated in manual or auto mode. The auto mode allows the
burners to change their firing rate and ratio in unison with the progression of the
furnace melting. This allows for maximum heat input and oxygen lancing during
the early states of each charge while there is still cold scrap in the furnace. The
rate will automatically be adjusted as the charge melts.

The following are typical firing modes:

• Protective/Hold:
This is a reduced flow that allows sufficient flow through the burner to
prevent clogging on flat bath conditions.

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 • Hot Fire:
This refers to a mode of operation that typically has a 2:1 up to 3:1
oxygen/gas ratio. The flow is varied to get the required energy input. The
flame obtained is to preheat and melt scrap. There can be several different
sizes of hot fire flames in auto mode.

• Soft Lance
Soft Lance is a mode of operation that is designed to promote efficient post
combustion operation. The flame is oxygen rich with ratios up to 7:1
oxygen/gas. In addition to post combustion the flame also cuts scrap that
has been preheated with the HOT mode.

• Lance Mode:
Fires the burner in the supersonic mode at a high oxygen/gas ratio. This
enables a supersonic jet to be produced that will cut the scrap and/or
decarburize liquid metal.

• Disable:
This is available on some systems and should be used if the burner must be
shutdown for any reason.
Note: This mode should be used in conjunction with manually closing the
appropriate gas train leg. This should not be relied on as the only means of
lockout.

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Table 1 – Operating modes of PTI JetBOx

Operating mode Function Flame example

Hot fire – multiple flame Scrap preheating and melting
structure highly efficient Two stage combustion flame
oxy-fuel flame (up to 6
MW)

Soft lance – piercing, Scrap cutting with rigid oxygen stream – middle
oxygen rich flame Post combustion CO with soft oxygen – oxygen rich
softer envelope

SS lance – Mach 2 – Decarburisation, energy introduction and bath agitation

supersonic shrouded Supersonic jet stream – middle
oxygen injector (up to 55 Oxy-fuel flame shrouding
Nm3/min oxygen flow) Post combustion of CO with excess of oxygen

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5.0 Installation Considerations

5.1 Refractory Installation

• There is a gap between the bottom of the box and the brick. This is filled with a
monolithic basic refractory. If there is room for a rammer head, the space may be
rammed with a basic ram. Failing that, a short pipe may gun it with a wet high
MgO gunning mix. In any case the installation must ensure there is refractory
material all the way back to the shell.

• If the box will have refractory bricks that butt up to the sides of the box, it is
important to ensure a tight joint at the copper box interface. Lay full brick adjacent
to the JetBOx. If some keys need to be cut, place them in the course some distance
from the brick/box interface.

• In the upper slag line area directly underneath the box, we recommend a high
quality carbon magnesite brick that contains a metal addition. This will minimize
oxide penetration and brick erosion.

• The interface between the water-cooled shell and the JetBOx must be designed to
minimize any gap between them. This gap should be less than ½ inch and packed
with ceramic wool before the joint is gunned with refractory material.

• Before the first heat, the joints around the box are built up with gunning material.
This will ensure a good seal around the box. After several heats sufficient buildup
around the box will prevent any slag penetration.

• The first heat after a shutdown is often long with poor foamy slag. We recommend
gunning the water-cooled panel joints if the possibility of splashing occurs. This
will ensure that the panels can be easily changed if required in the future.

Jet Box Sealed

to Panels

Burner Kept Clean

During Gunning

Jet Box Sealed

to Brick

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5.2 Mechanical Installation Points

• The addition a protective plate over the back of the JetBOx assembly may be
needed to prevent the burner and water hoses from being struck by falling scrap.

• Before start up the JetBOx should be checked to be sure the bottom is at right
angles to the metal bath with the furnace on level. This ensures proper impingement
angle to the bath.

• Water connections and fittings must be designed so as to be certain that no

restrictions occur.

• The water supply and return must be added to the safety checklist for furnace start
up procedures to make sure that supply and return valves are open before starting
the furnace.

• An independent water supply and return connection back to the shell header is
recommended for the box and burners.

• Manual valves should be installed on the gas, oxygen and water lines close to the
burner. These should be used, in addition to the main manual valves, when the
burners are serviced or changed.

• Water valves should be installed so as to ensure that scrap that might fall from the
bezel ring would not close the valve by accident.

• RTD’s should be installed on the exit (return) line to detect over temperature
conditions. (Note: Some installations have interlocked the high temperature so that
if a high temperature occurs the burners revert to hold fire.)

5.3 Water System Considerations

Special care must be exercised when one of the following conditions apply:
• New water system piping and water cooled elements.
• Extensive work on the water systems that might produce a extraordinary amount of
“sluge or dirt” eg. Cleaning cold wells etc.
• Water systems that have been moth balled or sitting for extended periods, dry or wet.

In cases such as the ones described above, there is a real danger of material being trapped in
the PTI equipment and causing poor cooling characteristics or in the worst case failure. It is
therefore strongly recommended to flush the system without connecting to the PTI
equipment before start up. This can be easily accomplished by coupling the hoses used for
the PTI water system together and allowing the system to flush for a minimum of 8 hours.

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 5.4 Oxygen System Considerations

With the installation of new piping for oxygen, a consideration in addition to degreasing
must be the cleanliness of the pipes with respect to particulate matter. During installation it
is possible that a large amount of metal and oxide debris can accumulate inside the pipes.
This can travel at high velocity inside the pipe that will cause a spark which in turn ignites
and material that may be accumulated on the screen found on the oxygen line.
PTI strongly recommends that the oxygen supplier be contacted to provide correct
procedures to clean the pipes of debris.
In addition, upon star up the screen should be inspected after each hour of operation until no
debris is found on the oxygen screen.

6.0 General Burner Safety Considerations

There is an inherent danger in the operation of combustion equipment of any type. With
an understanding of the equipment and good operational practice, you will be able to
confidently operate the oxy-fuel combustion system.

The major safety consideration inherent in the operation of this system deals with gas.
When gas is allowed to dilute in open air, the gas concentration is beyond its lean
flammability limit and is inflammable. However it cannot be allowed to accumulate in a
closed vessel such as an EAF. This is why care must be taken when igniting the
burner/injectors. This is the only chance for gas to accumulate. The steps to be taken in
preventing this are to verify that the furnace is sufficiently hot before attempting to light
the burner/injectors, and to visually verify that each burner/injector has ignited
successfully. If care is taken to insure that these two considerations are met the biggest
safety issue can be eliminated.

Other considerations that do not deal directly with the operation of the system but should
be followed as general practice guidelines include using oxygen compatible hoses and
components in the oxygen lines, and periodically checking for gas leaks in the system.

6.1 Water

PTI JetBOxes installed inside the hot furnace shell are water-cooled and it is
always the possibility of water leakage as a result of short circuits, or arcing, or
mechanical damage of equipment during the charging the scrap and hot metal.
PTI equipment is similar to other water-cooled elements inside the EAF. All
safety instructions and recommendations that apply to water cooled panels are
fully applicable to the PTI JetBOx system.

• The combustion chamber requires a minimum of 15 gallons per minute (57

liters per minute) to ensure good cooling effect. The JetBOx requires 95
gallons per minute (360 liters per minute).

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 • Temperature measuring devices (RTD) that monitor the outlet and inlet
temperatures should be checked regularly to ensure they are operational.

• Manual shut off valves on the supply and return of the burner and JetBOx
water should not both is closed on a hot furnace. This can cause a build up of
steam on the device, with possible explosion/burn consequences.

• Every start up after a downturn (or any extended downtime when

maintenance work had been performed) should include a check of valves to
ensure the water has not inadvertently turned off.

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Water Leak Response.

In the rare occurrence of a water leak from a JetBox failure, SAFETY is of paramount
importance. Water and liquid steel/slag will explode violently if mixed, therefore it is important to
rigidly follow procedures to safely contain and eliminate a water leak when one occurs.

What to do if a Water leak is identified.

Identify the magnitude of leak.

Is the water pooling on surface of molten bath?

Evacuate personnel to safe area until all water evaporates from inside furnace.

Immediately lock furnace movements and power off.

(Movements of the bath and arcing can mix water and steel)

Shut off water to smallest area possible to stop leak.

Isolate damaged component and slowly return water to other circuits.

Replace component and resume normal operation.

Is it spraying into furnace and evaporating?

Although each facility has different procedures for these types of water leaks, it is PTI’s
position that ALL water leaks be treated seriously and be corrected immediately.

Identify leaking component by temporally isolating water to individual circuit.

Insure no pooled water and replace failed component.

Resume normal operation.

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6.2 Lighting Burner

• Natural gas ignites spontaneously at approximately 1400° F.(760 C ) If the

furnace is hot, the burners can be shut off and restarted as long as it has not
cooled below that temperature. This is best done one burner at the time in
manual mode on holding/protective fire.

• On a cold furnace if the oxygen and gas leak into the furnace, a subsequent
ignition source can cause an explosion in the furnace, baghouse and
ductwork. For this reason, the P.L.C. is programmed that will not allow the
burners to start until a minimum number of K.W.H. are used. This is usually
around 3000 K.W.H.

• Similarly, if the furnace and burners have been off longer than predetermined
amount of time (typically about 15 minutes), it is again necessary to arc to a
predetermined K.W.H. setting. Note: If arcing occurs during the later stag
of a heat, without the burners on protective fire, burner blockage can
occur.

The following page is a recommended procedure for manually lighting burners.

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 Procedure for Manual Ignition of Burners
Purpose
Initial start up of the burner system will require that the burners are lit in order to verify
HOLD fire and burner operation. This is best accomplished with two or more personnel.

Equipment
• Overhead crane
• Fuel oil
• Rags
• Wire
• Two way radio

Procedure

1. Check and close all manual oxygen and gas valves at the burner.
2. Open all manual valves on the gas train and check to be sure you have the required
pressures.
3. On the MMI go to PERMISSIVE screen and depress reset button. (The kWh permissive
must be forced in the PLC in order to clear all the permissive.) All permissive light
should be green.
4. Depress and hold SYSTEM START button 2 seconds. Button should turn green
indicating the system is ready.
5. A quantity of rags and oil should be wired on the crane chain at this point and ignited.
6. The crane should be directed to the first burner to be lit, and the flaming rags positioned
directly in front of the burner.
7. At the MMI the selected burner should be MANUALLY be place in the HOLD mode.
This will open the automatic valves and pressurize the gas and oxygen lines to the
furnace. Note: Personnel should stay back from the burner at this point until it is verified
that hoses are not going to blow off etc.
8. The manual gas valve should slowly be opened, until the natural gas or LPG ignites.
After ignition open the manual gas valve 100%
NOTE: The two way radio communication is essential.
9. Once the gas is lit the oxygen manual valve can SLOWLY to 10 to 25 percent open.
When the burner becomes noisy stop opening the valve. NOTE: It takes several minutes
for the pressure built up in the oxygen line to dissipate. The burner can now be left and
the next burner lit in a similar fashion.
10. After several minutes keep opening the oxygen valves until they are 100% open

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6.3 Lockout

• It is good practice to manually lock out the gas and oxygen main valves if
the furnace is down for repair days or extended periods of time.

• If one burner needs to be shutdown, it should be locked out on the gas train
as well as the indication on the M.M.I.

Note: DISABLE mode at the MMI is only electronic indication and cannot
be relied on as a lock out.

6.4 Emergency Stop

• All combustion systems are designed with an emergency stop, to shut off all
the gas and oxygen. This typically is a red mushroom button on the
operators control panel as well as one on the gas train enclosure. Pulling the
button out will reactivate the system.

6.5 Valves

• Manual shut off valves for gas, oxygen and cooling water are located in
close proximity to the burners. These allow a quick shut off for
maintenance and repair purposes but should be used in conjunction with a
lock out for repair work.

• One way check valves are located in each gas and oxygen line to prevent
backflow. These should be inspected regularly for damage.

• When work is preformed on the burner, the oxygen and gas should be
manually locked closed.

• Valves should be protected from damage by scrap or hot materials.

• The flow control valves are set for specific hold fire flows. The hard stop
on these valves are set to allow a specific flow even when the valve is
100% closed. These valves do not shut off the flow of gas or oxygen.
These valves control the flow of gas and oxygen when the system is in
operation.

• Hold fire should be readjusted if the header pressure is changed for either
gas or oxygen. The following page contains a procedure for adjusting the
hold fire gas and oxygen.

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PTI System Hold Fire Adjustment (for both oxygen and gas valves)

Adjustment Screw Adjustment Screw

Lock nut

Use the adjustment screws to adjust hold fire.

1. Put burner or system in Hold Fire

2. Loosen Locknut on each side of FCV Valve (refer to M02 DWG)
3. Adjust setscrew as follows:

• Clockwise to increase Hold Fire

• Counter-Clockwise to Decrease Hold Fire.

4. Make one small and equal adjustment of both screws in sequence. 1/8 turn at a time.
5. Be sure to adjust both screws equally, they should both be tight to the valve at the same time to
balance the force, if one is looser than the other correct by tightening the loose screw.
6. Tighten locknuts when finished.

Installation

Refractory Installation

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 • There is generally a gap between the gland panel and the water-cooled panel. PTI’s
recommendation is to fill any gap with a monolithic basic refractory. If there is
room for a rammer head, the space may be rammed with a basic ram. Failing that,
a short pipe may gun it with a wet high MgO gunning mix.

Burner Assembly, Cleaning & Tolerance

• Combustion Chamber to Burner Fit

When the Combustion Chamber is

attached to the Burner, there is a gap
between the burner and the combustion
chamber.

As the burner and combustion chamber wear, this gap

may get smaller. HOWEVER, A GAP MUST EXIST.
If there is no gap, the burner is not making proper
contact with the combustion chamber and the burner will
not get the proper cooling. NO GAP WILL LEAD TO
BURNER MELTING & FAILURE!

• Burner Orifice Cleaning

Fig 7.2.1 – Clogged Burner

Fig 7.2.2 – Repaired Burner

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Occasionally, the burners get filled with gunning material when the burners are turned off
for furnace repair. Sometimes the burners are turned off during scrap charging or the
hold fire is set too low which leads to slag and steel clogging the burner orifices.

After removing the combustion chamber, the excess slag and steel can be removed from
the burner face with a brass brush. DO NOT USE A STEEL BRUSH, AS THE BURNER
FACE IS COPPER AND WILL BE DAMAGED.

Any steel or slag that has penetrated an orifice should be drilled out. The super sonic
nozzle is large enough that debris rarely accumulates in this orifice. However, if any
steel has gotten into the nozzle, DO NOT TRY TO REPAIR. Damage to the supersonic
nozzle may cause poor oxygen injection performance. Send this burner back to PTI for
nozzle replacement.

USE CAUTION WHEN DIGGING OUT DEBRIS FROM A BURNER ORIFICE WITH
A PUNCH OR ROD. PTI does not recommend digging out material with a punch or rod
as debris could be pushed further into the burner body and cause the burner to fail.

PTI recommends the use of a drill bit that is the same size as the orifice. There are
several burner sizes, make sure you consult the burner drawings for the correct orifice
size for your burner before choosing a drill bit.

• Burner Orifice Tolerance

Super Sonic Oxygen Nozzle

Shroud Fuel Orifice

Shroud Oxygen Orifice

Fig 7.2.3 – Burner Orifice Configuration

The burner orifice for both the fuel and oxygen will wear over time from use and from
repairs. All orifices should not be allowed to wear more than 1/16 of an inch from the
original size. Any further wear may contribute to failure of the annulus wall that may
result in a catastrophic failure of the burner.

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6.6 Oxygen Safety

Oxygen is a high pressure, oxidizing bas that vigorously accelerates combustion.

• All materials in contact with oxygen should be degreased of all organic

materials.

• Oxygen is supplied at pressures that can cause severe damage to personnel or

equipment. Care must be taken to ensure no accidental discharge.

• Personnel working on oxygen should wear grease free clothing etc.

• Any work performed on the oxygen system should be at atmospheric

pressure.

6.7 Natural Gas / LPG Safety

These gases are from the chemical family of paraffin hydrocarbons. The major
hazards associated with these gases are flammability and asphyxiation due to
concentration build up in areas of insufficient ventilation.

Natural Gas and LPG is a very effective fuel sources, however, safe handling is very
important with any combustible gas. Natural gas should be contained in leak free piping
and only delivered to the burner when there is assurance of an adequate source of
ignition. The EAF is carefully monitored to determine if the ignition source is adequate
by monitoring the energy delivered to the furnace. The input requires a KWH input to
determine when it is safe to start the combustion system.

• Gas train rooms should be well ventilated and be protected from all sources
of ignition.

• Any detected leaks should be repaired immediately.

• Carbon dioxide or dry chemical extinguishers should be available.

6.8 Flashback Control

By its design the copper water-cooled JetBOx and burner combustion chamber is
resistant to flashback. To ensure trouble free operation, a temperature-measuring device
should monitor water temperature on the return water pipes. This water temperature
reading is sent to the PLC. If there is a serious obstruction is in front of the JetBOx the
temperature will raise on the outgoing water.

The logic in the PLC has two temperature set points HI and HIHI. The HI mode indicates
a warning by a yellow light on the operators screen. At HIHI the PLC automatically
places the JetBOx in the HOLD mode to reduce the rate of chemical energy input. As the
temperature cools to HI the JetBOx resumes normal operation. The steel plant has the
option of using the HIHI signal to also shut the furnace power off.

This system not only protects the JetBOx but also the surrounding water-cooled shell.

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7.0 Operating Procedures

7.1 System Start up

The main utilities, gas (for future burner operation), oxygen, electricity, and water must be
connected and turned on before the system can operate.

The following outline will illustrate the steps necessary for operating the injector (or
burner) system.

1. Verify that the manual oxygen and gas utility shut-off valves are opened at the main
inlet to the flow control train, at each of the individual injector (or burner) branches on the
flow control train, and at each of the injector (or burner) locations around the furnace.

2. Verify that all of the valves for each of the pressure and differential pressure
transmitters on the flow control train are open. These valves should only be closed when
calibrating the transmitters; otherwise they should remain open.

3. Verify that the cooling water supply and return valves are open at each injector (or
burner). Also verify that water is flowing through the injector (or burner). This can
usually be done by feeling the injector (or burner) combustion chamber, the water pipe or
the water hose.

4. Verify that the E-stop buttons located on the flow control train and in the operator’s
pulpit are not activated.

5. Clear any alarm faults.

6. Activate the system. This will open the main automatic shutoff valves and pressurize
the system.

The burners are now ready for lighting.

Before attempting to start the burners, verify that there is enough energy in the
furnace to promote ignition.

7. System Safety Features

• The system is equipped with interlock that requires a sufficient amount of
electrical energy input (usually about 4000 kWh) in the furnace before the gas
and oxygen automatic shutoff valves for the burner system are permitted to open.
• If no energy has been introduced into the furnace for a certain amount of time
(usually 15 minutes) and the furnace is allowed to cool, the burner are not
allowed to be relit if the flame is extinguished until the requirements of this
interlock are met again.

When starting up the burners place each burner one at a time into HOLD fire and visually
verify that the burner flame has ignited before continuing to the next burner. If the burner
has not ignited after approximately 15 seconds shut the burner off and wait until there is
more energy in the furnace.

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 8. The injectors (or burners) may now be placed in AUTO MODE for normal operation.
In this mode, the injectors (or burners) will cycle through their pre-set firing mode
schedule. The cycle is driven by the electrical input into the furnace.

7.2 System Shut Down

When the system is to be shut down for extended periods of time the following procedure
should be followed.

1. Burners are placed in HOLD mode.

2. SYSTEM OFF button is pushed in MMI. This closes all automatic valves.

3. Valve train main and individual valves are closed.

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8.0 Troubleshooting Guide

Problem Causes Corrective Action

• Burner combustion system • Oxygen plant has exceeded • Long term solution requires
trips on high oxygen high pressure switch setting proper pressure regulation.
pressure. If arcing on combustion system.
continues without
protective fire burners will
block.

• Burner combustion system • Oxygen plant can not • Wait until system pressure
trips on low oxygen deliver sufficient oxygen is re-established. Reset and
pressure. If arcing supply. restart combustion system.
continues without • Modify firing schedule to
protective fire the burners reduce oxygen use.
will block • Investigate consumption
characteristics of other
users on oxygen system.
• Burner combustion system • Gas regulator failure • If system has a regulator,
trips on high gas pressure. • If system has no regulator, verify proper function.
If arcing continues without supply of gas is not Note: When the system
protective fire burners will regulated. trips gas will vent to
block. atmosphere.

• Burner combustion system • Gas regulator failure • Verify repair regulator if

trips on low gas pressure. If • If system has no regulator, required.
arcing continues without supply of gas is not • Ensure sufficient supply of
protective fire burners will regulated natural gas.
block. .

• Burners not reaching set • Burner orifices are plugged • Check supply pressures to
point on gas and / or with material. ensure sufficient pressure.
oxygen flows • Supply pressure is not • Clean burners if clogged
sufficient. • Visually inspect HOLD fire
• Control valve is sticking for sufficient flame
velocity.
• Ensure HOT fire is initiated
before charges are dropped.
• Verify control valve
operation
• Copper combustion • Insufficient water flow due • Check and insure water
chamber water leaks. to low pressure system maintains a
• Accumulation of dirt in the sufficient inlet pressure and
water passage of the low back pressure.
combustion chamber. • Ensure proper water
• Adding lime through the cleanliness.
roof before the scrap is • Add lime through the roof
sufficiently melted. late into the melting cycle
• Adding lime in the top of when scrap in front of
the scrap bucket burner is gone.
• Do not add lime on top of
bucket.

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Troubleshooting Cont

Problem Causes Corrective action

• Excess splash of slag and • Insufficient slag in the later • Do not slag off to early
metal on roof and or walls stages of heat • Start carbon flow just
• Using supersonic without before initiating supersonic
any slag foaming flow if in manual mode.
• Introduction of supersonic • Do not initiate supersonic
mode to early in melting until bath is established and
cycle scrap mostly melted.

• Carbon pipe blocked • Purge air shut off • Ensure purge air is not shut
• Air flow less than 2.5 off while furnace is
Nm3/min (95 scfm) operating.
• Hole in line causes purge • Check air flow and
flow to be reduced to pressure.
unacceptable levels • Check and do preventive
maintenance on conveying
lines and pipes.
• Excessive wear on carbon • Coke/ coal cut steel and • Use coal which is less
injection pipes. rubber piping abrasive
• Reduce carbon particle size
to maximum 0-2 mm or
smaller.
• Check that air flow
(velocity) is not excessive
• Flow is still indicated on a • Blocking valve/ solenoid is • Change valve/solenoid
burner with the system in defective
the OFF mode
• Carbon injection pipe • Pipe protrudes to far into • Make sure pipe does not
difficult to change furnace and is welded with protrude into the furnace
steel and/ or slag. • Use heavy walled pipe
• Pipe is out of round causing Schedule 80 or 160 that
extraction to be difficult will not distort during
• Pipe is “mushroomed’ at operation or hammering
the end • Always drive pipe into
furnace on furnace turn
around. (don’t pull out)
• Make a slide hammer to
drive pipe into furnace
• Protect end of pipe with
wood (or similar material)
when hammering
• Coat new pipe with
graphite paste when
installing.

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9.0 HMI Guide

The following is a picture of a generic PTI HMI control screen. Your HMI screen may look different
depending on what PLC and control software you specified for this project. A customized HMI manual
can be produced for your system upon request.

Figure 1 – General HMI screen

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 9.1 System Auto Mode (outlined in black)

Use this drop down box to choose the automatic program. Standard systems include five (5)
auto modes. More modes can be added if needed (at additional cost). Some systems use a
drop down box and other systems have individual buttons.

Instructions for the Auto Mode setup are shown in section 9.4.

Figure 2. – System Auto Mode

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 9.2 Manual Mode

These buttons (outlined in black) located on the left hand side of the screen, manually control
the burner/lance.

• System Hold – burner mode. Low velocity flame intended for holding fire during scrap
charge or waiting when the burners should not be turned off.
• System Hot 1 – burner mode. Low energy flame used for preheating scrap. Usually set
between 1 – 1.5 MW.
• System Hot 2 – burner mode. Medium energy flame used for preheating scrap. Usually
set between 1.5 – 2.5 MW.
• System Hot 3 – burner mode. High-energy flame used for preheating scrap. Usually set
between 2 – 4.5 MW.
• System Soft Lance – Lance mode. Excess oxygen flame used to cut scrap. Oxygen ratio
is usually 10 or higher. Burner runs at high oxygen level. May need to increase car bon
injection to compensate for added FeO levels in the slag due to high oxygen usage.
However, cost of carbon consumption usually offset by operation improvements.
• Manual Lance or system SS lance – lance mode. Super sonic Oxygen lance. Oxygen
travels at Mach 2 for up to 2 meters. Length of flame is controlled by temperature in
combustion chamber. Therefore, the higher the gas usage, the longer the flame. Most
furnaces do not need 2 meters to reach the steel bath with the oxygen. It is possible to
run a reduced gas flows and still maintain efficient de-carbonization rates. The exact gas
flow needed for each furnace must be determined empirically.

These buttons control all of the installed burners as a group. Instructions for the manual
burner set up are located in section 9.4.

figure 3 – manual burner controls

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 9.3 Individual Burner Controls

Each installed burner has individual flow and cooling water temperature displays. Each
system will only show the installed burners. The example figure shows three installed
burners. However, your system may have more or fewer burners depending on the system
you purchased.

By clicking on the Burner display box, the controls for that burner are shown. The individual
burner can then be changed to a mode with out affecting the other burners.

Figure 4 – individual burner controls

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 When the burner control box (outlined on the previous page) is clicked, a pop up box for
individual burner controls appears. This control box will allow the operator to change the
current mode of an individual burner with out affecting the auto program. The auto program
continues to run even if one of the burners is placed in a manual mode.

Manual burner control continued

figure 5 – individual burner control box

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 9.4 Auto and Manual Set Up

Click the Auto Set Up or the Set Up button to open the set up screen. The location of the
button may not be in the same place as the example. However, the button is usually located
on the side or bottom frame of the main screen.

Figure 6 – set up screens

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Auto set up continued

The set up screen will look similar to the following example. The Auto and Manual modes are
sometimes shown on the same page (as in this example) or they are sometimes on separate pages
depending on software configuration and system limitations.

1. The program, burner and charge mode to be changed are selected from the drop down
boxes. Some programs have buttons instead of drop down boxes.
2. KWH The program operates by following a set burner and lance patter that is dependent
on kWh count. The kWh set points can be tailored to each furnace and operation. No
operation is the same, therefore, several programs can be written to accommodate
different steel grades or scrap mixes utilized by the process.
3. Gas The gas flow is input into the program in Nm3/hr
4. Oxygen The oxygen flow is input into the program as a ratio of the gas flow. This
allows an intuitive oxygen flow to be chosen based on stoichiometric characteristics of
the fuel used by the operation.
5. CI Carbon injection is input into the system as kg/min.
6. Manual Mode Setup The fire rates for the manual modes – both group and individual are
controlled by the gas and oxygen flows input into the manual mode input box.
7. Read from and Write to PLC. The Read from PLC button must be pushed every time the
program, burner or charge is changed. If a change is made to the setup: First, enter must
be pushed after every input change. Then, the Write to PLC button must be pushed for at
least 3 seconds to verify the write command. Either a red button will illuminate on the
screen or the button itself will turn green to indicate that the write command was
successful

2
3 6
4
5
7
7

figure 7 – changing set up of burner controls

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 9.5 Burner Set Point and Present Values

The current set point and current present flow rates for each burner are summarized on the
main screen.

Figure 8 – system flow and set points

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 9.6 Heat Consumption and Charge Control

The total consumption of kWh, gas and oxygen are summarized on the control box outlined
in black. The current charge is also displayed in this control box. The charge will
automatically index to the next charge. However, the operator can change the charge
manually as needed.

Figure 9 – charge control and system utility usage summary

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 9.7 Alarms and Reset
The alarms for the burner system are shown in the outlined box. Green indicates that the
system is OK. A red light indicates a high or low alarm point was reached. After the
problem is corrected, the Reset button is pushed to clear the alarms.

Figure 10 – system reset control

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10.0 Maintenance Schedule Matrix Combustion System

# Item Inspection Description of Inspection/ Repair

Description Period
1.0 Gas Train
• The gas train should be cleaned of
excess accumulation of dust etc
1.1 General Monthly • Check valves and gauges for damage.
• Check fittings and joints for gas and
oxygen leaks.
Check pressure drop across the strainer by
Oxygen and observing pressure gauges on either side of the
1.2 Weekly
NG Strainers strainer. If the pressure differential is more
than 5 psi, clean the screen
Pressure
Check 4-20 ma signals by applying calibrated
1.3 Transmitters Annually
pressure.
and DPTs
Isolation
Each Repair
1.4 Valves • Check for operation and damage.
Day
At Burner
1.5 Check Valves 6 months • Check operation
• Check all hoses and fittings.
• Check hot face of JetBOx for
Each Repair
2.0 JetBOx damage.
Day
• Check carbon pipe for wear.
• Check RTD & TC heat protection
• Check tip of combustion chamber for
wear.
Each Repair • Check hold down bolts
3.0 Burner
Day • Check burner for damage.
• Check for blocked gas and oxygen
orifices.
Return burner to PTI to check valve operation
3.1 Burner Annually
and general inspection

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11.0 Quality Requirments for instrument air/N2 .

Maximum amount of suspended particles 1 mg/Nm3

Maximum diameter of particles 0.001 mm

Dew point -20 ˚C

Maximum amount of suspended oil 1 mg/Nm3

12.0 Quality Requirements for Cooling Water

PH 7-9 pH

Calcium (Ca) 30-360 mg/litre

Magnesium (Mg) 0-120 mg/litre

Alcalinity 50-300 mg/litre

Chlorides max 250 mg/litre

Sulphates max 200 mg/litre

Iron max 0.5 mg/litre

Silica (SiO2) max 75 mg/litre

TDS(Total Disolved Solids) max 1500 mg/litre

TSS ( Total Suspended Solids) 50-80 mg/litre

TSS size( Total Suspended Solids Size) max 200 µm

Oil max 10 mg/litre

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