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| Oxygen Probes |
The Minox Oxygen Probe, consisting of a thermocouple and oxygen cell sensor tip and paper tube immersion vehicle, along with the accompanying instrumentation and hardware, measures the dissolved oxygen content of a liquid metal within 5 to 7 seconds. This tool, first used successfully in the US on a production basis in a BOF in 1978, has been responsible for changing steelmaking from an art to a science. The results of successful employment of the oxygen probe in steelmaking are:
The two outputs from the probe, which are evaluated and displayed by the instrumentation, are the temperature from the thermocouple and the mV output from the oxygen cell. The instrument uses these output values as variables in a widely used standard equation to calculate the oxygen content, which is also displayed. The System The system consists of an oxygen probe, a steel pole with a contact block on one end and a handle and connector on the other end, a lead wire with a connector on both ends and an instrument. Teflon Stainless Steel Braided 4 wire compensated cable, green 4 wire teflon compensated cable, 4 wire compensated pole end sensor connector, male and female compensated cable and pole end cable connectors, bo peep hande and replaceable pole lance holder connector assembly. The Oxygen Probe is pushed onto the steel pole. The contact wires on the probe mate with contacts in/on the contact block. Inside the steel pole is a cable of three or four wires. This cable, attached to the contact block, carries the electrical outputs of the thermocouple and oxygen cell to the connector that is attached to the handle on the other end of the pole. The cable is designed to withstand the heat from the steel during a test. The connector in the handle is attached to a lead wire by a connector on one end of the lead wire. This lead wire carries the electrical outputs of the probe to an instrument, attaching to the instrument through a connector on the appropriate end of the lead wire. The instrument can stand alone or can be attached to the process computer of the steel mill.
The Oxygen Probe Paper Tubes Length The tip/paper tube assembly can be obtained in several lengths, typically 4', 6' and 8' although other lengths that are less than 8' are available. The proper length is dictated by the amount of heat to which the section of the steel pole adjacent to the open end of the paper tube is exposed. Too short a probe will heat the pole excessively, burning the internal cable, causing unnecessary pole consumption and high hardware cost. Minco recommends a tube and thickness length which minimizes the amount of heat to which the steel pole is exposed. Internal Dimension Three paper tube ID's are available, depending on the requirements of the customer: 3/8", 1/2" and 3/4". Hardware for the probe is specific to the ID of the paper tube (see Hardware). The 3/4" size is the most durable. The 3/8" size is used in smaller furnaces or ladle and requires a lance holder (see Hardware, located on the Products Page, for more Oxygen Probe details). The design of the contact block is not able to withstand the rough treatment, dirt and moisture that the 3/4" size can withstand. Note that the three ID's are available to satisfy the needs of a customer. However, the 3/4" size has the strongest probe and pole: the pole for the 3/4" size is the easiest to build and the consumption of hardware is the lowest. Minco recommends the use of the 3/4" size in all application, even in the smallest furnaces and ladles.
Hardware Contact Block The appropriate contacts on the contact block, which is attached to one end of the steel pole, mate with the connector wires on the probe tip. The three or four wires that protrude from the end of the contact block that is inside the steel pole are attached to the three or four wires in the cable which is inside the steel pole. The signals from the probe are transmitted to the cable inside the steel pole through the contact block. Each ID of probe, 3/8", 1/2" and 3/4" has a specifically designed contact block. Steel Pole The steel pole consists of a steel pipe, a contact block on one end of the steel pipe, a handle with a connector on the other end of the steel pipe and three or four wire cable inside the steel pipe. The three or four wires that protrude from the end of the contact block that is inside the steel pole are attached to the three or four wires in the cable that is inside the steel pole. The other end of the three or four wires of the cable are attached to the connector that is attached to the handle on the other end of the pole. The pole carries the oxygen probe into the liquid steel. It is protected from the liquid by the paper tube of the oxygen probe. The signals from the oxygen probe are transmitted through the connector that is in the handle. Each ID of probe, 3/8", 1/2" and 3/4" has a specifically designed steel pole. The steel pole for the 3/8" ID probe consists of a contact block, a lance holder, a 3/4" ID section of steel pipe, a handle with a connector and an internal cable. The length of the lance holder onto which the probe is pushed, is dependent on the length of the oxygen probe paper tube. It is screwed to a section of 34" steel pipe that completes the overall length of the steel pole. The contact block fits into a recess in the end of the lance holder and is secure by a roll pin. The standard handle is screwed to the other end of the steel pipe. The internal cable electrically joins the contact block to the connector in the handle. The steel pole for the 1/2" ID probe consists of a contact block, a 1/2" ID section of the steel pipe, a handle with a connector and an internal cable. The contact block in two pieces, is screwed into one end of the steel pipe. The two pieces are secured together with a roll pin. The standard handle is screwed to the other end of the steel pipe. The internal cable electrically joins the contact block to the connector in the handle. Internal Cable The internal cable, consisting of three or four wires, joins the contact block to the connector in the handle. Two high temperature-resistant designs are available:
The mineral-insulated, copper swaged cable with leads protruding from each end can be compromised if the seals on the ends are broken, allowing moisture to enter the copper tube and short the internal wires together. The length of this cable must be chosen carefully before ordering, since adjustments to length are very limited. The ability to withstand high temperatures is superior to the wire mesh cable. The fiberglass-insulated, stainless steel wire mesh covered cable is supplied as a roll that is cut to length by the customer. It is recommended by Minco if a probe length which minimizes the heat that the exposed portion of the steel pole experiences is utilized. Handle The handle, standard "Bo Peep" style, screws onto the steel pipe and has thread to accept a connector. Handle Connector The female connector in the handle is screwed into the handle. It connects to a male connector on one end of the lead wire that joins the pole to the instrument. Lead Wire The lead wire joins the pole to the instrument. It consists of four wires and two male connectors, one on each end.
Steel Industry Applications BOF Furnaces The time and expense of stopping a BOF blow process restricts the number of times that the furnace can be tested economically. Charge and blow models are developed to eliminate reblows: therefore, the use of oxygen probes in the BOF is limited to an end point measurement or to an additional measurement after a reblow. The applications of oxygen probes in a BOF are, thereby, limited: although, they are very cost-effective. Calculation of Carbon Content The oxygen content and temperature, determined after turndown, are used in a previously determined equation that correlates the oxygen content and temperature to the carbon content of the liquid steel. The rapid acquisition of the results, 5 to 7 seconds allows the melter to make judgments about the disposition of the heat: i.e., whether to reblow for high carbon content (or low temperature) without waiting for the analysis of a solid sample from the lab, saving many dollars in heat time. Calculation of the Amount of Deoxidizers or Alloys to add to the Ladle During Tapping The oxygen content, determined as close to tap as possible, is used to calculate the amount of deoxidizers or alloys to add to the ladle during tapping. This greatly enhances the ability of the melter to hit the aim chemistry. The amount of deoxidizers to add during tapping can be based on previously determined equation(s) that use the oxygen content, temperature, actual heat weight, grade, chemistry of the liquid, aim chemistry, amount of slag carry over, tap hole condition (oxygen pick up). The addition(s) can be determined by past history, with reliance on the experience of the melter, while considering the oxygen content and the previously stated variables. BTO-Bomb Temperature and Oxygen The BTO, a free-fall device that contains a thermocouple and oxygen cell, is dropped into the upright BOF vessel via a drop system that is located above the mouth of the upright vessel. The BTO gives results that are identical to the conventional oxygen probe. But, it allows the melter to test the BOF without the expensive and time-consuming turndown, increasing the flexibility of the application of the oxygen content to the BOF process. The elimination of the turndown saves money in many ways. Calculation of Carbon Content The oxygen content and temperature, determined close to the calculated end of blow, are used in a previously determined equation that correlates the oxygen content and temperature to the carbon content of the liquid. The rapid acquisition of the results allows the melter to make judgments about the disposition of the heat: i.e., whether to continue to reduce the carbon content through additional oxygen blowing, to process the head further for temperature, to turn the furnace down for further testing or to tap the heat. Calculation of the Amount of Deoxidizers or Alloys to Add to the Ladle During Tapping The oxygen content, determined by the BTO, is used to calculate the amount of deoxidizers or alloys to add to the ladle during tapping. This greatly enhances the ability of the melter to hit the aim chemistry. The amount of deoxidizers to add during tapping can be based on previously determined equation(s) that use the oxygen content, temperature, actual heat, weight, grade, chemistry of the liquid, aim chemistry, amount of slag carry over, tap hole condition (oxygen pick). The addition(s) can be determined by past history, with reliance on the experience of the melter while considering the oxygen content and the previously stated variables. Electric Arc Furnaces As a result of the ability to test in the EAF at any time after the scrap has melted, the oxygen content can be measured many times during a heat. This expands the applications in an EAF over those in a BOF, allowing the results of the test to be used as a tool to control the heat through the control of the oxygen content.Calculations of Carbon Content The oxygen content and temperature, determined at any time during the heat, are used in a previously determined equation that correlates the oxygen content and temperature to the carbon content of the liquid. The rapid acquisition of the results allows the melter to make judgments about the disposition of the heat: i.e., whether to continue to reduce the carbon content through oxygen blowing or to process the heat further for temperature without waiting for the analysis of a sold sample from the lab, saving many dollars in heat time. Calculation of The Amount of Deoxidizers of Alloys to Add to the Ladle During Tapping The oxygen content, determined as close to tap as possible, is used to calculate the amount of deoxidizers of alloys to add to the ladle during tapping. This greatly enhances the ability of the melter to hit the aim chemistry. The amount of deoxidizers to add during tapping can be based on previously determined equations that use the oxygen content, temperature, actual heat weight, grade, chemistry of the liquid, aim chemistry amount of slag carry over, tap hole condition (oxygen pick up). The addition(s) can be determined by past history with reliance on the experience of the melter, while considering the oxygen content and the preciously stated variables. Calculations of the Amount of Sacrificial Aluminum Or Ferroaluminum to Add to the Ladle During Tapping A variation of the preceding application, specific to non-aluminum-killed EAF shops, was developed in the early 1980's. In this variation, the oxygen content is determined immediately prior to tapping. This is used to calculate the amount of aluminum or Ferro-aluminum to add to the lade at the beginning of tapping to reduce the average oxygen content in the ladle to a level that permits high and stable efficiencies of the alloys but prohibits the retention of dissolved aluminum in the steel. Typically, only minor changes to the standard alloy additions have to be made as the result of the final oxygen content in the furnace the actual heat weight and the chemistry of the liquid in the furnace. Determination of the End of Oxygen Blowing This application is a combination of two of the previous applications, calculation of carbon content and calculation of the amount of deoxidizers or alloys to add to the ladle during tapping. An ideal tap oxygen content can be established for all grades in an EAF shop. This ensures that the proper carbon content is achieved and that the heat will not be overblown, standardizing the amount of deoxidizers or alloys. Results of tests of oxygen probes taken during the heat process can tell the melter when the oxygen blow can be stopped or whether the heat should be sampled prior to tapping, without having to wait for the analysis of a steel sample, saving many dollars in lab costs and heat time. Typically, only minor changes to the standard alloy additions have to be made as the result of the final oxygen content in the furnace, the actual heat weight and the chemistry of the liquid in the furnace. Ladles-Aluminum-Killed Steel Calculation of Aluminum content. The use of oxygen probes at an LMF in a ladle that contains, or should contain aluminum-killed steel is to ensure that the proper aluminum content has been achieved, without having to wait for the analysis of a solid steel sample. This is accomplished by the correlation of the oxygen content and temperature to the aluminum content. The results from a test with an oxygen probe are used in the equation to calculate the aluminum content of the steel. The rapid acquisition of the result allows the operator to make judgments about the disposition of the heat; i.e., whether to add more aluminum or to process the heat further for temperature or to obtain the final solid sample for analysis by the lab, without waiting for the analysis of a solid sample. Non-Aluminum-Killed Steel-Castability The absence of high aluminum levels in some casters is essential for proper castability of the liquid. The result of an oxygen probe test in the ladle at the LMF can show the presence of detrimental levels of aluminum or the lack of sufficient alloys (Mn and Si) without waiting for the analysis of a solid steel sample. Oxygen levels that are less than 6 or 7 ppm indicate the presence of high aluminum levels. Oxygen levels in excess of a previously determine maximum level, which is dependent on the desired C, MN and Si contents, indicate insufficient levels of these elements. Additions of C, MN or Si can be based on the analysis of a solid sample, heat weight, and chemistry spec. The additions can be made on the basis of experience, considering the oxygen content, temperature, heat weight and chemistry spec. Prevention of Porosity Another application of the oxygen probe in the on-aluminum-killed steel is to ensure the proper oxygen content in the ladle to prevent pin and blow holes. The carbon content and various caster characteristics dictate the proper oxygen level. These can sometimes be achieved without the use of aluminum or calcium, again, depending on the carbon content and various caster characteristics, but some grades require the use of some aluminum and/or calcium. The results of an oxygen probe test will determine whether these deoxidizers are necessary, when the additions can be made and the amount to add.
Other Non-Ferrous Applications The Ni/NiO electrochemical cell can be used in many specialized applications in the Nonferrous molten metals industries such as Nickel Smelting. Summary Oxygen probes not only determine dissolved oxygen content, but also can be used to infer the content of other species in the molten bath in equilibrium with that oxygen, such as sulfur. Oxygen probes are fast, accurate, and inexpensive and coupled with the Minco MetNet system give producers a complete measurement system, which can be integrated into existing plant control systems. Oxygen probes assist in standardizing processes, leading to reduced costs, reduced process cycle times and improved quality. Quality Control The control of the quality of the Minox Oxygen Probe is responsible for:
The former is related to the control of the construction of the oxygen probe and the latter is related to the control of the consistency of materials that are used in the construction. The QC begins with extensive testing of all materials and constructions in the Minco one ton induction melting furnace. Heats are conducted many times per month, depending on the testing requirements. The testing procedures are confidential. Live testing demonstrations have, can and will be given to present and potential customers. Such demonstration may be arranged through the Sales Manager of Minco. Minco also applies a stringent ISO 9000 quality plan to all phases of the construction of oxygen probes. The success of these quality procedures and the design of the Minco oxygen probes are evident through the high success rates and excellent process and chemistry control that are realized by our customers. |