SIEMENS says its LDS6 laser gas analyser is helping to improve safety and prevent damage at the Tasmanian Electro Metallurgical Company manganese ferroalloy plant.
According to TEMCO, the manganese ferroalloy plant depends on the Siemens LDS6 laser gas analyser to alert workers to imminent furnace explosions in the submerged arc furnaces, so they can prevent it.
TEMCO claims submerged arc furnaces are some of the most dangerous furnaces in the world. They are vulnerable to sudden explosions due to the temperature control mechanism used in the furnaces.
To maintain the internal temperature, water is pumped through a series of tubes inside the furnace. Over time, the water erodes the steel tubes and water leaks into the furnace. The extremely high furnace temperatures and water leakage can cause the build up of steam, which eventually leads to an explosion.
Siemens says its implementation of the LDS6 laser gas analyser was the first time the unit had been used in submerged arc furnaces. The extremely high levels of dust at the facility were a major challenge, as dust can erode the accuracy of the laser analyser.
Siemens modified the LDS6 laser gas analyser to address the challenge. It built an air chamber to blow the dust off the laser every few minutes, allowing the unit to retain its consistent and reliable readings.
As a result of a set of control limits, the analyser can detect water leaks hours before traditional methods. This allows the LDS6 gas analyser to forewarn of future explosions, so plant workers can take the appropriate measures.