Large-scale Air Separation Unit for Steel Mill
Product Overview
Large-scale Air Separation Units for Steel Mills provide continuous, high-purity oxygen, nitrogen, and argon directly to Blast Furnaces, BOFs, EAFs, and DRI plants. Engineered for 24/7 non-stop operation, these systems integrate cryogenic distillation, process automation, and optimized refrigeration to ensure a reliable gas supply for modern steelmaking operations.
Industry-Specific Advantages
Uninterrupted High-Volume Supply: Built for multi-year continuous operation, supporting heavy steelmaking loads with zero unscheduled down-time.
Metallurgical Oxygen Purity: Delivers oxygen at ≥ 99.6% purity, meeting exact standards for BF enrichment, BOF decarburization, and EAF burner injection.
Wide-Range Load Turndown: Smoothly adapts gas output from 50% to 105% capacity to match variable steel mill production schedules without dropping product purity.
Multi-Gas Revenue Maximization: Simultaneously captures high-purity nitrogen for inerting and liquid argon for stainless steel production, maximizing overall air utilization.
Applications in Steel Manufacturing
Blast Furnace (BF): High-volume oxygen enrichment to boost pig iron productivity and reduce coke ratios.
Basic Oxygen Furnace (BOF): Rapid oxygen blowing for efficient carbon removal and melt refining.
Electric Arc Furnace (EAF): Chemical energy assistance via oxygen-fuel burners and lancing.
Direct Reduced Iron (DRI): Reformer gas synthesis and process gas cooling/protection.
Continuous Casting & Processing: High-purity nitrogen for molten steel shielding and cutting operations.
Parameter
Oxygen
|
Output |
Purity |
Pressure |
|
Single set 20000-100000+Nm ³/h |
≥ 99.6% |
Oxygen consumption for blast furnace:~0.8-1.6 MPa Oxygen for converter: 2.5-3.5 MPa |
Nitrogen
|
Output |
Purity |
Pressure |
|
About 2-3 times the oxygen production |
99.999% (≤ 10 ppm O₂) |
Multiple types: from low-pressure blowing to medium pressure spraying. |
Argon
|
Output |
Purity |
|
Approximately 5% -12% of oxygen production |
≥ 99.999% |
Operation and energy consumption
|
Unit oxygen consumption |
Annual operating time |
|
0.35 – 0.45 kWh/Nm³ O₂ |
≥ 8,300 hours |
(For reference only)
Engineering & Customization Scope
We customize each cryogenic system according to local plant utilities and operational targets:
|
Design Parameter |
Customization Scope |
|
Oxygen Capacity |
Engineered to project requirements (Nm³/h) |
|
Delivery Pressure |
Customized per furnace injection specs (BarG) |
|
System Configuration |
Double-column / Single-column / Argon recovery |
|
Automation Architecture |
Siemens / ABB / Honeywell PLC & DCS Systems |
|
Electrical & Safety |
IEC / ANSI / NEC / ATEX compliant design |
|
Compressor Selection |
Centrifugal air / booster compressor matching |
|
Site Adaptation |
Extreme climate, altitude, and utility-water design |
Project Execution & Delivery
Technical Consultation: Gas demand analysis and energy optimization study.
Process Engineering: PFD, P&ID, HAZOP analysis, and 3D layout modeling.
Manufacturing: In-house fabrication of heat exchangers, cold box, and pressure vessels.
Pre-Shipment Testing: FAT inspection, instrument calibration, and packing validation.
Site Execution: Turnkey supervision, cold-box perlite filling, and pipe integration.
Commissioning & Training: System cooldown, performance test run, and site crew safety training.
Engineering Support & After-Sales
On-site installation supervision and commissioning management.
24/7 remote diagnostics and process optimization assistance.
Original spare parts management and preventative maintenance programs.
Field operator training covering regular operation, safety protocols, and emergency procedures.
FAQ
Q: How does the ASU respond to sudden oxygen demand fluctuations in the steel mill?
A: The automated control system monitors pipeline pressure in real time and automatically regulates compressor guide vanes and column valves. This enables smooth load adjustments between 50% and 105% of rated capacity while maintaining steady purity.
Q: Can a liquid storage backup system be integrated into the ASU design?
A: Yes. We integrate liquid oxygen (LOX) and liquid nitrogen (LIN) storage tanks with automated ambient vaporizers to provide seamless standby gas supply during power outages or ASU maintenance.
Q: What critical utilities must the steel mill provide for site installation?
A: The site must provide primary electrical power, cooling water circulation, instrument air, and a level foundation. Exact electrical load and water consumption figures are defined during the preliminary engineering phase.
Q: Is it possible to connect the new ASU to our existing mill gas piping and DCS?
A: Yes. Our automation team custom-designs communication interfaces (Modbus, Profibus, Ethernet/IP) to link seamlessly into your centralized plant DCS and existing gas distribution networks.
Q: What international design codes and manufacturing standards can you comply with?
A: Equipment can be designed and certified according to ASME, CE/PED, GB, ISO, IEC, and local safety standards based on the final project destination.
Q: What technical supervision is provided during installation and commissioning?
A: We dispatch certified mechanical, electrical, and cryogenic process engineers to supervise site assembly, cold box perlite filling, system cooldown, and initial performance run until stable gas output is achieved.
Q: What key factors determine the overall CAPEX and OPEX of a steel mill ASU?
A: CAPEX is governed by required oxygen capacity, argon recovery inclusion, and backup storage size. OPEX is primarily driven by local power costs, compressor energy efficiency, and cooling water temperatures.
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