Gas-blending station for a hot strip mill
As part of the modernization of the Duisburg production site, a new mixed-gas station was to be built for thyssenkrupp Steel Europe’s Hot Strip Mill 4 and seamlessly integrated into the existing gas supply network. The plant plays a central role in steel production and must provide process gases safely, consistently, and reliably at all times. In addition to the high requirements for availability and operational safety, the project involved integrating a wide variety of measurement, analysis, and monitoring systems into an existing industrial environment. At the same time, customer-specific plant standards, explosion protection requirements, and integration into existing control and automation systems had to be taken into account. Implementing the project within an active production environment was particularly challenging, as all work had to be precisely coordinated and carried out without disrupting existing processes.
gefeba handled the complete EMSR engineering design as well as the planning, delivery, installation, and commissioning of the electrical infrastructure. The project included the implementation of extensive cable routing systems, structured field cabling, and modern measurement, control, and regulation technology. In addition, switchgear, network, and distribution cabinets were installed and connected to the higher-level control and automation systems. A particular focus was placed on gas measurement technology. To this end, Wobbe and analysis containers, ambient air monitoring systems, and measurement points for pressure, temperature, and differential pressure were integrated. In addition, Venturi and orifice measurements were implemented using the appropriate measurement technology. To reliably determine the Wobbe index, an analysis container with a complete testing and supply infrastructure was installed and integrated into the automation system. In addition, gefeba installed condensate collection tanks with monitoring and measurement technology, integrated gas detection systems, and set up redundant power supply systems with UPS units and mains transfer switches. Components in potentially explosive areas were consistently designed with explosion-proof construction.
The close integration of engineering, control panel construction, field installation, and commissioning resulted in a high-performance, future-proof control and measurement solution for a central gas supply system used in steel production. The new WBW4 mixed gas station ensures a safe and stable supply of the necessary process gases to the hot strip mill while also creating optimal conditions for the further modernization of the production site. Thanks to the integrated measurement, analysis, and safety technology, a high degree of transparency, operational safety, and plant availability has been achieved. The new plant thus makes an important contribution to supply reliability, increased efficiency, and the long-term sustainability of the Duisburg site.
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We develop customized solutions—from analysis through the engineering phase to commissioning and support. Our focus is on maximum functionality, on-time delivery, and durability.
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