EAF Monocator (Electric Arc Furnace Repair System)
EAF Monocator (Electric Arc Furnace Repair System)
The EAF Monocator is a robot which uses sophisticated computer control to target wear areas in the furnace wall and hearth. This offers a much safer and less labour intensive option than the conventional manual spraying. See our literature for further information. The system can be divided into three components:
- The Monocator Robot: This is capable of moving the applicator from its parked position alongside the furnace, over the furnace wall into the furnace, and of adjusting its height to reach each position of the lining that requires maintenance.
- Material Delivery: A material delivery system designed to provide a constant delivery of material to the applicator at up to 15 tonnes per hour for the wet side wall material and 30 tonnes per hour for the dry hearth material. The application is achieved by utilising a patented spinning disc technology that allows discriminate programmed patches to be applied anywhere in the furnace.
- Control System: The control system is computer/P.L.C. controlled, housed in the EAF pulpit. The computer is programmed to control all movements of the applicator and to command the material delivery system.
Design Features
EAF Monocator Design Features
- Designed to be user friendly.
- Can be used in Automatic or Remote Radio Controlled modes.
- High level of operator safety.
- Robust construction Monocator Arm and frame.
- Integral Material feed system: 2.0 cubic metres Bulk Hopper, with 6 Barg Pressure Vessel and material Delivery of 5.0 cubic metres/hour (max).
- Integral Weigh system with digital display.
- Integral Water system with temperature control.
- PLC based Control Panel.
Safety Benefit
EAF Monocator Safety Benefits
- The radio controller functionality ensures that the operator is positioned remotely from the application / heat source and moving machinery.
- Emergency Shut-off.
- No crane required during maintenance.
Technical Specification
EAF Monocator Technical Features
The machine is a fabricated mild steel construction with access covers where necessary. The EAF Monocator is mounted on a base plate which will be fixed in place on the caster floor.
The Electrical Control System will typically consist of the following:
- PLC Panel - typical supply; 220/110V single phase.
- Control Console - typical supply; 220/110V single phase.
- Inverter Panel - typical supply; 415V, 3 Phase, 50 Hz.
- Wireless Radio Controlled Joystick.
- PLC based Electrical control panel: Standard is Mitsubishi PLC. (Other options are available).
- Integral Material Feed System: 2.0 cubic metres Bulk Hopper, with 6 Barg Pressure Vessel and material Delivery of 5.0 cubic metres/hour (max).
- Integral Weigh System: Display quantity of dry material, Load Cells on Feed System and Digital Display on Control Panel.
- Integral Water system: 200 Litres capacity, Multi-stage pump with control valve, digital flow meter and temperature control.
Supply Options
EAF Monocator Supply Options
- Touchscreen Monitor (for furnace repair control from the control room).
- The EAF Monocator can be upgraded with a second feed system to apply fettling material to the EAF hearth and banks.
- Optional integrated refractory scanner for repairing specific areas in the furnace according to the residual lining thickness.
- Alternate PLC Panel options are available such as an Allen Bradley unit with Ethernet/IP protocol or Siemens PLC with Profinet.
- UPS - mains power spike/failure protection
EAF Monocator Installations
A few examples of previous Monocon EAF Monocastor installations are shown below.
Cost Benefit
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