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Feb
022022
Feb
022022
SARRALLE a key player in the steel industry, design and supply metallurgical plant equipment, including process technology for steelmaking, secondary metallurgy and continuous casting machines. We provide innovative and integrated solutions for complete process areas, including EPC projects.
The aim of SARRALLE is to evaluate and recognize every aspect of your needs: from the concept phase through the erection of the equipment including the development of the layout, definition of the processes, to the engineering and fabrication of the equipment. Our installations pay attention to both energy saving and effective pollution reduction, essential criteria for the sustainable development of your company.
Our installations consist on the following equipments:
SCRAP CLEANING
Sarralle Scrap cleaning equipment improves the melting process, obtaining benefits such as reducing the consumption of energy, raw materials, refractories and electrodes. At the same time, this type of equipment will allow better process automation and greater respect for the environment.
The main objective of the installation of this machinery is to reduce energy consumption in the electric arc furnace. The installation of a scrap preparation system allows the applied energy to be concentrated solely on the fusion of iron-based materials. This avoids the energy expenditure that currently occurs in heating loose hearth and refractories, plastic and rubber elements, cellulose and non-ferrous materials that accompany scrap metal.
This kind of installation has been designed to process from 80 to 150 tons of scrap per hour, depending on the scrap qualities. The operation of this plant is fully automatic, with control through a PLC and a fault display. This display can show a synoptic chart with the current status of the plant.
The advantages that our technology provides are the following:
Energy saving
Electrode saving
Productivity increase
NOx reduction
CO reduction
ELECTRIC ARC FURNACE (EAF) – BLUE EFFICIENT ARC®
SARRALLE Blue Efficient Arc® - Electric Arc Furnaces are based on decades of experience providing our Customers with an innovative design and high-quality manufactured equipment supported by our highly experienced technical staff.
SARRALLE designs and produces a complete range of AC and DC Furnaces from 6 to 300 metric tons for various charge mixes (scrap, HBI, Cold DRI/Hot DRI and Hot Metal), based on our in-house engineering and including all key components, such as:
Automatic slag door with scrap pushing and sill cleaning function
Full platform design with a single tilting hydraulic cylinder.
Conductive electrode arms of box-shape design made of copper & steel plates.
Roof with single lifting point.
Water-cooled components with an intensive water flow design solution which results in a reduction of 25% of required water quantity.
Burners and oxygen injectors.
Water-cooled copper boxes for injector installation on the EAF shell.
Injectors for carbon, lime and any other solid materials.
Electrics & automation (level 1 & 2)
Electrode regulations system
Automatic sand filling device
Automatic sampling device
Liquid bath weight controlling system
Fully reproducible automated melting process conditions and instructions regardless of the type of raw material selected.
Reduced energy consumption to 300 - 350 kWh/ton of liquid steel with optimized chemical energy packages.
Electrode specific consumption in the range of 0,9 kg/ton - 1,2 kg/ton of liquid steel with the assistance of the electrode breakage approaching.
LADLE FURNACE (LF)
Complete range of Ladle Furnaces from 6 to 340 t with simple and very sturdy design, based on proprietary engineering of all the supplied components:
Roof with inert atmosphere based on special skirt-type design.
Water-cooled components with intensive water flow using 25% less of required water quantity.
Side-mounted roof lifting mechanism.
Conductive electrode arms of box-shape design made of copper & steel plates.
Twin LF station for highly productive melt shops.
Swinging roof solutions for limited room areas in melt shops.
Ladle self-loading stations to reduce the work-load on melt shop cranes.
Automatic sampling & temperature lances.
Wire feeding systems starting from the coil to a complex guiding System.
Automatic couplings for stirring gas connection to the ladle.
Emergency stirring lances.
Electrics & Automation (Level 1 & 2)
Electrode regulation system.
Injection technology for solid materials (slag builders, carbon, calcium carbide, etc..).
VACUUM AND OXYGEN DEGASSER (VD, VOD)
Sarralle VD-VOD units can be engineered to operate with steam injectors or dry mechanical vacuum pumps to achieve deep vacuum with lowest energy consumption in shortest pump down time.
Whereas steam ejector vacuum pumps offers a simple, almost maintenance-free solution with high suction capacity and a minimal investment cost, dry mechanical vacuum pumps are characterized by instantaneous “vacuum on demand” with extremely low operating costs and elimination of water contamination.
Special foaming-slag control enables minimization of ladle slag overflow and pump-down time.
SARRALLE supplies:
Vacuum vessels
Oxygen lances
Sampling equipment
Vacuum batch hoppers
Vacuum cyclones/bag filters/gas coolers
Vacuum pumps
Water-cooling systems
VACUMM INGOT CASTING (VIC)
The Sarralle Vacuum Ingot Casting process is applied to produce forging ingots of 100-800 metric tons. Steels for the production of such ingots should contain very low hydrogen level, typically below 1ppm.
Sequence casting of several smaller heats into one very large ingot.
Vacuum degassing of steel takes place during casting (exposing of the poured stream of steel into the vacuum of less than 2 mbar).
Optionally, liquid steel can be partly degassed in a standard tank type degasser prior to vacuum ingot casting.
The ingot mold is placed on the bottom of the vacuum tank
A pony ladle, placed on the vacuum tank cover above the vacuum-tight discharge connection to the vacuum tank acts as a tundish, reducing ferrostatic pressure of the steel flowing into the ingot mold and allowing several ladles to be cast into the same ingot mold.
Steam Ejector or Mechanical Vacuum Pumps can be used for the generation of the necessary vacuum level during casting.
Additional liquid steel temperature losses associated with other vacuum degassing processes are avoided.
Thanks to the exposing of smaller volumes of steel stream into the vacuum conditions, the efficiency of degassing is higher, which results in a lower level of hydrogen in the ingot
Compared with standard casting conditions, additional pick-up of hydrogen from the atmosphere can be avoided
Ingots much larger than the furnace capacity of the furnace providing liquid steel can be cast easily
CONTINUOUS CASTING
SARRALLE Continuous Casting Machines have been engineered through the integration of innovative technical solutions and a wide range of experience in process technology, thereby safety, quality of the final product and reliability of the equipment offered to our Customers is guaranteed. SARRALLE Continuous Casting Machines are designed for a wide range of section sizes, operational flexibility and steel grades which include:
Billet - Round - Bloom - Beam Blanks - Slab.
Open and submerged tundish to mold casting operation.
Standard structural and SBQ steel grades.
FUME EXHAUST SYSTEM (FES) – BLUESKY- PLANT®
Our Fume Exhaust Systems (FES) exceeds the most restrictive environmental regulations and enhances the social responsibility. Our Customers are leading to an increasing demand for investments in dedusting and pollution control technologies. The Fume Exhaust System fulfills all current and expected environmental requirements specified by local authorities.
SARRALLE offers customized solutions for each step of the process with satisfactory results in attaining the most stringent parameters in terms of both emissions control and operational costs. Each component has its own design, such as the special arrangement of the fourth hole elbow water circuit with an optimized life cycle.
Residence time in the canopy due to superior geometry selection enables a lower amount of mg/Nm3 on the operating floor, which leads to an improvement in the safety for every operation. Filtration parameters allow an optimal life cycle of the sleeves, as well as the selection of the optimized number of compartments automatically maintaining at least, one offline compartment. Optimized bags length of up to 10 meters permits a compact design of the Filtration Unit.
Design features include:
High-tech combustion chamber.
High-efficiency quenching tower with either an air-mist water only or nitrogen based system.
Special canopy design to improve working conditions of the melt shop building.
Low water consumption technology for the fume cooling system.
Improved controls for air mixing.
Lignite and lime injection.
High-efficiency fumes sparks separating cyclone.
With decades of experience in the steel industry, both providing new steel plants or revamping the existing equipment, SARRALLE is an ideal partner with extensive know-how and experience in supporting every step in the EPC project with Engineering, Manufacturing, Site Construction and Commissioning of complete steel plants.
