Metals Production

Metals Production

For many years, engineers have relied on process mass spectrometers to analyze, calculate and control various steel and aluminum manufacturing processes. Metal production and processing applications such as Basic Oxygen Process (BOP)Blast Furnace analysis, Gas Mixing stations, Vacuum Oxygen Decarburization (VOD) batch processing, Heat Treating processes and Metal Coating processes benefit from the accuracy and speed of online process analyzers. Today, Extrel’s MAX300-RTG™ Industrial Process Mass Spectrometer are in use in steel production and aluminum processing plants worldwide.

A few of the advantages of our systems include:

  • Real-time fast analysis of gas compositions at multiple points
  • Analysis enabling precise air control, optimizing ore reduction
  • Allows the user to calculate and control the amount of carbon remaining in a product
  • Allows the user to calculate the rate of decarburization and identify the endpoint of the VOD processes
  • Detection levels for contaminant compounds in coating and specialty metal processes at the parts per million (ppm) level

Extrel has been producing quadrupole mass spectrometers for over 45 years. We work closely with our customers to understand their obstacles involving their applications. Our expertise in developing the specific products our customers need has established our reputation as the world’s leading supplier of gas analysis systems, mass spectrometers and components.

Extrel supports a variety of industry standards and communications including Ethernet, Bi-directional Modbus, RTU or TCP/IP, OPC, Analog and Digital outputs and custom communications.

Metals Production Applications

Basic Oxygen Process (BOP)

Process mass spectrometry has been used for decades to improve the Basic Oxygen Process (BOP) and successfully produce high quality stainless steel. Process Engineers rely on the BOP to calculate and control the amount of carbon that remains in the liquid metal batch. The BOP uses oxygen to burn excess carbon, converting it to carbon monoxide and carbon dioxide. The percentage of eliminated carbon is calculated using measured concentrations of the carbon monoxide, carbon dioxide and the gas flow rates. Since the gas flows extremely fast, calculations need to be made as quickly as possible.

Blast Furnace

The Blast Furnace remains an important part of today’s steel production industry, and Extrel’s MAX300-RTG™ Industrial Gas Analyzer continues to provide the analytical information today’s process engineers need for optimum process control.

Extrel’s MAX300 Series is relied on for a multitude of measurements, such as:

  • Analysis of the reducing gas at several different levels within the blast furnace ...

Gas Mixing Stations

Today’s steel manufacturing plants produce more than just steel; they have the ability to create usable fuel gas for their processes. During many of the steel processing phases, the spent gas streams containing various levels of combustible gases can be burned to create usable fuel. However, to ensure a quality fuel gas, it is important to know more than just the BTU value. The exact composition of the combustible components is crucial for process control.

Because these streams are recycled process streams, compositions vary greatly. Various waste streams and makeup gases are mixed at a Gas Mixing Station to ensure a good quality fuel. Because the Extrel Mass Spectrometer determines the exact component composition, engineers have come to rely on Extrel’s MAX300 Series Mass Spectrometers in the gas mixing application.

Vacuum Oxygen Decarburization (VOD)

VOD, a manufacturing process that ensures the quality of stainless steel, relies heavily on fast and precise measurements of stream compositions during various stages of the process. The speed and accuracy provided by the MAX300-RTG™ Industrial Process Mass Spectrometer meets the VOD application’s fast analysis requirement. The real-time analysis provided by this analyzer system enables VOD processes to be optimized for efficiency and product quality.

The MAX300-IG Industrial Gas Analyzer has been designed to:

  • Analyze all 7 components of the full exhaust in less than 3 seconds
  • Display the rapid changes in component concentrations during each phase of the process

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Extrel CMS, LLC 
575 Epsilon Drive
Pittsburgh, PA 15238
USA