Implemented Projects

Batching and loading system and PCS for Material Handling System of Furnace #12 of Melting Shop #1 are aimed for automatic monitoring, analysis, coordination and adjustment of basic parameters for batching, transportation and loading of charge materials into Furnace #12 of Shop #1. 

The aim of this upgrade was the replacement of extremely old and worn out process equipment of Material Handling Sector #42 of Shop #4 and fixed control system, thus it became possible to move to a new quality level of monitoring and control of the charge materials batching and loading into the furnace.

Scope of Work and Services

• Development of technical requirements to the automated control system for charge materials batching of Material Handling Sector of Furnace #12 of Shop #1
• Development of a technical assignment and design documents for the process line and PCS of Material Handling Sector of Furnace #12 of Shop #1
• Development of design documents for a weigh car
• Manufacturing and supply of process equipment (continuous belt batcher, belt conveyor, inclined belt conveyor, weighing bin with a gate, mobile loading device)
• Manufacturing and supply of PCS equipment for Material Handling Sector of Furnace #12 of Shop #1
• Installation supervision and commissioning

Basic Technical Parameters of Process Line

 Note:  MPL - maximum performance limit

Process Line Components

• Storage bins
• Weighing belt batchers
• Collecting and inclined belt conveyors
• Monorail retractable car
• Furnace hoppers

Functions

• Automatic monitoring of loaded charge components and adjustment of additional loading in order to support the proportion of components as per the formula
• Monitoring of the process equipment state (batchers, conveyors, intermediate bin, weigh car)
• Control over the conveying system (inclined and collecting conveyors, weigh car)
• Automatic loading of furnace hoppers
• Metering the materials supplied into furnace hoppers
• Monitoring and displaying of the system operation and operator's actions (proper batching of components, adding extra materials, control of batching system etc.) 
• Data exchange with database server

Features

• The required accuracy of batching has been achieved, quality mixing up of charge components has been provided through additional loading and layer-by-layer batching onto the belt of the collecting conveyor
• The performance of the batching system has been enhanced by using continuous batchers, an intermediate bin and reduction of the car travel distance
• The compliance with process requirements has been provided due to the central transfer of process data with their consequent treatment, recording and displaying at the work stations
• Timely and quality loading of Furnace #12 of Shop #1 and its proper operation have been provided