Cvs dss ftp_project description


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General Description of Fume Treatment Project for DSS company in Ukraine by CVS MAKINA , which is designer, manufacturer, erector companies for all the units for meltshop and rolling mills explaining themselves as the dedicator to steel sector.

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Cvs dss ftp_project description

  1. 1. DNEPROSPETSSTAL FUME TREATMENT PROJECT DESCRIPTION CVS MAKINA - Company Presentation -Design-Manufacturing Offices: - Erection - CVS Headquarter - Training (Turkey) - Consultancy - CVS Europe (Italy) -Innovation - CVS Egypt - Process - CVS Ukraine Development - CVS Iran
  2. 2. CVS MAKINA - Company Presentation CVS provides plants & equipment for minimills, also in “turn-key” solution. CVS covers the complete design and manufacturing activities for green-field projects as well as revamping/upgrading of existing plants and equipment. CVS manufactures spare parts & components for meltshops & rolling mills. CVS provides technical assistance and consulting service to steel production.CVS MAKINA - Company Presentation Quick Info CVS headquarter is placed in the industrial region of Gebze, just east of Istanbul, close to many major ports Our modern facilities consists of more than 40,000 sqm of closed area and a land of additional approx. 40,000 sqm CVS workforce is formed by over than 500 specialized workers and engineers with a modern machinery park to undertake even the most challenging projects. Over than 200 engineers and administrative employees are involved in the design and management of the projects.
  3. 3. CVS Why FTP Is Important? Why FTP Is Important? CVS Why FTP Is Important?Why modern dedusting systems are crucial Dust Emission - 10 to 25 kg/ton steel.The most important goals are high reliability, strict compliance with prescribedthreshold values reasonable energy consumption.CVS Advantages Cost-efficient production Maximized productivity Low consumption levels Short delivery times Consistently high availability Flexibility of charge material Preparation for future environmentalrequirements
  4. 4. CVS What FTP means for EAF?In the field of environmental protectioninside the electric steel meltshop, a veryimportant application is the collectionand treatment of the primary fumesproduced by the EAF process andescaping from the IV hole on furnaceroof. The emission flowrate,temperature, heat load and compositionare continuously and suddenly changingduring the power-on phases. The mainpollutant generated by the EAF processare the fine dust of iron oxide and otherheavy metals, volatile compounds, butalso the quantity of CO and VOC arehigh. CVS What to consider during decision?-To achieve high reliability and favorableoperating costs requires the right design.-The more cleanly the process parameters areadapted to one another and the more preciselythe design is tailored to the up-streamaggregate, the more smoothly the operationwill run.-Long-lasting, low-maintenance componentsvirtually eliminate unplanned downtimes.A dedusting system requires sensibleinvestments. That is why it is so important forthe system to be able to accommodate futureexpansions of production and potentiallystricter environmental regulations - withoutrequiring significant modification andconversion costs. And for the same reason,you need a plant layout that also offersflexibility for the future.
  5. 5. CVS - FTP Why to Choose CVS CVS Why to choose CVS?CVS offers the entire spectrum of dedusting technology from a single source, always inclose collaboration with our customers steel production plant specialists. This is ourapproach for creating perfectly coordinated, economically viable solutionsGood reasons for our dedustingsolutions•Guaranteed compliance withagreed-upon limit values•Tailored dedusting units usingcomprehensive mini-mill expertise•Future emission requirements arealready taken into account in theplant layout•Problem-free operation with lowservice requirements•Turnkey solutions from a singlesource - with one contact, and oneperson in charge
  6. 6. CVS - FTP Dedusting solutions for your EAF steel mill?Clean EnvironmentHigh availability, high reliability andguaranteed elimination of residues such asdioxin from an electric arc furnace. In otherwords, you produce steel while we makesure your systems and your environmentstay clean.Maintenance? Short, planned and efficientRobust components, high-qualityworkmanship and the right design keepmaintenance to a minimum. Our systemsalso allow bags to be changed duringoperation - another way we contribute tohigh availability.Equipped for future demands todayCVS designs your system to harmoniouslyaccommodate any future expansions withno long downtimes or start-up problems.Thus, with your initial investment, weve putyou on the right track to effectively limitingsubsequent costs later on CVS - FTP AUTOMATION Smooth operation - fully automated CVS automation ensures flexible, secure operation, a high degree of safety for people and machinery and high efficiency over the entire life-cycle of the system. Advanced solutions, such as an inverter for large drives, contribute to decreased energy costs by allowing output and energy consumption to be continuously adapted to production demands.
  7. 7. CVS - FTP AUTOMATION Operation of complete dedusting system is syncronised by automation system. Distribution of flow to primary and secondary section of EAF is controlled by two dampers located on the lines actuated automatically by automation.Damper position and main fan speedsaccording to 5 main modes of furnaceoperation can be changed by HMI in FTPcontrol room.Additionally, fan speed is adjusted duringmelting phase according to the value comingfrom pressure transmitter measuring thepressure inside combustion chamber. CVS Converter Off-Gas System WE FOLLOW LAST TECHNOLOGIES WHEN WE MANUFACTURE OFF GAS SYSTEMS
  8. 8. CVS -Converter Off-Gas System RESPECT TO THE NATURE
  9. 9. DSS COMPANY PROFILEA leader in production of special steel products, Dneprospetsstal (DSS) is based inZaporozhye, Ukraine, and employs about 6 200 people.Originally founded as a state-run enterprise in 1932, today Dneprospetsstal’s activities coverthe design, manufacture and distribution of stainless, tool, high-speed (including powdermade steel), bearing and alloy structural steel products.DSS’ products are used in the manufacture of machinery parts, tools for metal and alloymachining, seamless pipes and bearings.DSS enjoys a unique position as a high added-value producer. The company’s location inUkraine gives it a favorable geographical advantage, placing it in proximity to two of itslargest consumer regions: the CIS and the EU. With partners and distributors in more than15 different countries, DSS casts a wide net over world markets; its products are used andsold in over 60 countries.Dneprospetsstal aims at retaining leadership in the domestic market and expansion of itspresence in the markets of Russia, Europe, America and Asia using existing and newdistribution channels.The Company also strives for entering into strategic alliances and finding partners forcooperation in the field of subsequent metal processing. DSS PRODUCTION CHARTDneprospetsstalproduces morethan 800 gradesand 1000 cross-sections.DSS manufacturingprocess is anoptimalcombination ofdifferenttechnologicalprocedures, whichprovide making ofhigh qualityproducts withdesired properties,
  10. 10. DSS ECOLOGICAL VISION Goal To create an environmentally safe business.ResultInvesting significantfunds annually into Ideaenvironmental Environmentalprojects like protection meanspurification equipment concern aboutand the introduction of peoples healthenergy savingtechnologies. DSS FTP DECISIONDneprospetsstal constantly develops and modernizes production facilities, new technologiesdeveloped and up-to-date equipment implemented result in the highest quality productperformance.The following design criteria have been considered during the decision of the system:•minimum operation and maintenance costs;•optimal utilization of spaces inside / outside the meltshop;•automatic operation, “hands-off” type; and•twenty-four hours operation.
  11. 11. DSS FTP PROJECT PLANT PHOTO DSS FTP PROJECT GENERAL IDEAThe purpose of the new FTP is the control and treatment of the following emission sources: Primary emissions from the new 60 t E.A.F.; Secondary emissions from the new 60 t E.A.F.; Emissions from the new twp pcs. 60 t L.F.; Emissions from the new Material Handling System (MHS).;The main topics of the new FTP are listed below:•Suction of the EAF primary emissions from the IV hole elbow installed over the EAF roof;•Suction of the EAF secondary emissions from a canopy hood installed on the roof building;•Suction of the 2 pcs LF emissions from the side draft hood installed above the LF roof;•Suction of the MHS emissions from a set of dedicated local hoods;•Cooling of EAF primary emissions by means of a natural cooler (hairpin design);•Filtering of the dirty gases by means of a bag filter, pulse-jet bag cleaning & negativepressure type;•Exhausting of the cleaned gases by means of two main ID fans driven by AC motors withinverter;•Emission into the atmosphere of the cleaned gases by means of dedicated stack sized.
  12. 12. DSS FTP PROJECT DESIGNDesign considers following workingprofile:Melting phase•EAF in melting phase (roof closed,primary fumes suction line open);•Suction from the canopy hood toprovide meltshop ventilation and primaryfumes cooling;•LF in heating phase;•MHS in operation.Charging/Tapping phase•EAF in charging/tapping phase (roofopen, primary fumes suction lineclosed);•Suction from the canopy hood;•LF in heating phase;•MHS in operation. DSS FTP PROJECT PROCESS FLOWSHEET
  14. 14. DSS FTP PROJECT DESIGN VALUES EAF secondary emissions (canopy hood): 3 o •Suction capacity (tapping/charging): 800.000 Nm /h @ 80 C 3 o •Ventilation capacity (melting): 370.000 Nm /h @ C 3 •Actual fume flowrate (tapping/charging): 1.030.000 m /h 3 •Actual fume flowrate (melting): 440.000 m /h •Hot fumes spreading velocity approx. (charging): 2.20 m/sec EAF primary emission (melting phase): 3 o •Fume suction capacity: 45.000 Nm /h @1.600 C o •Fume temperature at cooler outlet: 300 C Ladle Furnace o •Suction capacity: 37.000 Nm3/h @ 150 C 3 •Actual fume flowrate: 60.000 m /h •2 LF total suction capacity: 74.000 Nm3/h o •Temperature at suction duct inlet:90 C 3 •2 LF Actual fume flowrate: 110.000 m /h Material handling system emission o •Suction capacity: 50.000 Nm3/h @ 50 C 3 •Actual fume flowrate: 60.000 m /h DSS FTP PROJECT BAG FILTER DESIGNTotal design capacity: m3/h 1.200.000Max. working temperature: °C 120Compartments: nr. 16Bag cleaning system: pulse jet off-lineCompartment off-line: nr. 2Total filtering surface: m² 14.855Net filtering surface: m² 12.998Clean gas dust content: mg/Nm³ 20Filter headers: nr. 16Blowing electro valves: nr. 264 – 2 incFiltering bags: nr. 4.224 pcsFiltering bag material: polyester needle feltFiltering tissue weight: g/m² 500Filtering bag dimensions: mm 160 x 7.000
  15. 15. DSS FTP PROJECT EAF PRIMARY EMISSIONSThe EAF primary emissions are controlled by a set of water cooled ducts (WCD) and radiant orsingle-walled ducts (SWD); while the final hot gas cooling is performed by the natural cooler.The system dedicated to the EAF Primary Emission consists of the following components: An elbow with duct, installed over the combustion chamber roof and provided with apneumatically adjustable sliding sleeve. The purpose of the sliding sleeve is to regulate the gapbetween the IV hole elbow (part of the EAF roof) and the consequent WCD line. Through thisgap the necessary external air is sucked to dilute the primary gas and to permit the COcombustion in the chamber. A combustion chamber made of water-cooled panels and concrete / refractory in the bottompart; it is sized to guarantee suitable retention time for CO full combustion and to allow forvelocity reduction to enable heavy particles to settle. A set of water-cooled ducts (WCD) are designed to cool down the hot gases coming from thecombustion chamber and to convey them up to the radiant ducts. A Natural Cooler designed to cool down the gases up to a temperature to allow the mixingwith the EAF Secondary Emission line. The Natural Cooler consists of a bundle of radiant ductsof suitable diameter to avoid clogging. A set of radiant ducts (SWD) of single walled type are foreseen to convey the gases from theWCD to the Natural Cooler. A regulation damper of multi-flaps type driven by electric actuator designed to adjust thesuction flow in the line. DSS FTP PROJECT EAF SECONDARY EMISSIONSThe EAF Secondary Emissions are controlledthrough the following components: A large canopy hood installed on the top of thebuilding roof and designed to collect the EAFemission during charging / tapping phases and tosuck the necessary dilution air to finally cool downEAF primary gases to reach a temperatureacceptable by the filtering unit. The canopy hoodvolume and shape are designed to allow anadequate “resident time” of the emission during theEAF most critical operating conditions. Two collectors of “trombone” type are installedinside the canopy hood to improve the internalsuction efficiency. A main duct line is foreseen to convey the secondary emissions from the two collectors to thefiltering unit. The diameter of the duct is sized in order to obtain an optimal internal gas speed(approx. 29-30 m/sec) to avoid dust settlement. An axial cyclone is installed upstream the filter unit in order to stop sparks and heavy particles inany operating conditions. A safety damper, pneumatically actuated for a quick response when gas temperature exceed themaximum continuous working temperature of the filtering unit (about 130°C).
  16. 16. DSS FTP PROJECT LF & MHS EMISSIONSThe control of the LF emissions is The following equipment carries out theperformed through the following control of the emission generated by thecomponents: Material Handling System:A side-draft hood set-up on LF roof top •A set of local suction hoods (to be definedand designed to collect the primary and sized by the Material Handlinggases generated by the LF (this hood System supplier) to be located as close asis part of the LF its self). possible to the emission sources.A set of radiant ducts of single walled •A set of radiant ducts to connect the localtype designed to convey the gases hoods with a common duct and thenfrom the side draft hood to the mixing connected with the EAF secondarypoint with the EAF secondary emission emission main ducts.main ducts. 3. A booster fan of centrifugal type isA booster fan of centrifugal type is provided to compensate the losses in theprovided to compensate the losses in duct, thus allowing an efficient suction.the duct, thus allowing an efficient The fan is driven by a LV motor and issuction. The fan is driven by a LV fitted with a regulation damper actuated bymotor and is fitted with a regulation electric actuator.damper actuated by electric actuator. DSS FTP PROJECT FILTERING UNITThe emissions filtration is carried out through one negative pressure bag filter with off-line pulse-jetbag cleaning design. This type of filter works in under-pressure with the main fans located afterwardand is equipped with an automatic bag cleaning system based on the use of compressed air jet intothe bags. The high efficiency of the bag cleaning system requires a reduced volume of injected air at lowpressure, thus reducing air consumption and pressure drop. The main advantages of suggesting filters are summarized as follows: - reduced overall filter dimensions, thanks to a filtering surface far lower than that of a filter cleaned by a reverse air operation; - fans located downstream the filter, consequently high efficiency impellers can be used thanks to the small dust content in the treated gas; no out of balance risk is faced; - reduce pressure drop thus low energy and compressed air consumption; - easy maintenance and bags replacing.
  17. 17. DSS FTP PROJECT BAG FILTERHuge flowrate calls for pulse jet filter which aresuction-type filters, equipped with compressed airautomatic bag cleaning system. The filter itself iscomposed of 2 parallel lines, made up of severalcompartments containing a fixed number of bags.Each compartment consists of a “raw gas”chamber below and a “clean gas” chamberabove divided by the bag supporting plate. Thelower chamber composes the filter body, containsthe filtering bags and the dust collecting hoppers.The upper chamber contains the injectors for thecompressed air distribution to the bags forcleaning purpose.The two chambers are connected to the central collector respectively to the gas inlet and outlet bymeans of separation dampers. Dampers for lower chambers are manually actuated, being utilizedin closed position as an additional safety in the event of maintenance or inspection; the dampers ofthe upper chambers, instead, are provided with pneumatic actuators, being automatically closedwhile performing maintenance and bag cleaning in OFF-LINE mode.The cleaning system of the filtering bags is located inside the “clean gas” chamber. It is composedof one distributor per row of bags, completed with compressed air feeder to each bag. DSS FTP PROJECT EXHAUSTING SYSTEMThe suction and exhaust of the various emissions is performedby the following equipment: Three centrifugal fans located downstream the filtering unit.The main fans are equipped with backward blades of highaeraulic efficiency and are driven by A.C. asynchronous electricmotors at LV. The speed of the main fans is variable andcontrolled through inverters. A plenum, made of concrete, is designed to receive thecleaned gas from the bag filter and equally distribute it to themain fans. In this way the turbulence created by the main fansare reduced improving their efficiency and decreasing thepressure drop of the whole system. A stack installed over the concrete plenum is designed to discharge the cleaned gases into theatmosphere. To reduce the noise level, the stack diameter is sized according to a gas speed ofapprox. 18 m/sec. A set of radiant ducts and collectors are foreseen to connect the bag filter outlet with theconcrete plenum, the plenum with the main fan inlets and the main fan outlets with the stack. A special silencer is installed between each main fan outlet and the stack to further reduce thenoise level at the required value.
  18. 18. DSS FTP PROJECT DUST HANDLINGThe dust and particles collected in the variousgeneration points of the FTP are evacuated indifferent ways depending from location. The dust and heavy particles collected in thecombustion chamber have to be removed when theEAF is not in operation by means of a bob-cat whichcan enter through the water-cooled door. The natural cooler hopper is fitted with a chainconveyor and a rotary valve to discharge the collecteddust into skip box. Similar to the natural cooler, also the axial cyclone hopper discharges the dust via a rotary valvedirectly into skip box. The bag filter is designed with pyramidal hoppers and the dust is removed via a conveyorsystem, which transfer the dust till a dedicated storage silo located in an elevated position. Thesilo is fitted with level sensors, a manual damper, a vibrating bottom and a rotary valve todischarge the dust on trucks. In connection with the natural conditions of an arrangement of FTP, the penthouse of filter isprovided in warm building designs. DSS FTP PROJECT CANOPPY HOODThe canopy hood is placed on the top of the building roof above the EAF and has the purpose tocollect the emissions generated during charging & tapping phases of the EAF. Besides, it has theduty to ventilate the building during the EAF power-on phase and to such the necessary dilution airto finally cool down the primary emission temperature before to be processed by the filtering unit.The shape and volume of the canopy hood depends on several factors, such as:•distance between EAF mouth and bottom line of the canopy hood•EAF shell diameter•position of the EAF in the bay•geometrical shape of the building roof. The canopy hood is designed to allow an adequate “ resident time “ of the fumes during the EAF most critical operating conditions (i.e. charging and tapping). Another important factor taken in due consideration for the canopy hood design is to avoid the “flow back” phenomena. In fact, proper dimensioning of the canopy hood can give enough volume to destroy kinetic energy of downward fumes.
  19. 19. DSS FTP PROJECT PELLETIZERThe pelletizing machine transforms thedust collected by the bag filter intonodules through the addition of a binder(water), which is sprayed in a rotaryplate. The pellet forms owing to theirrolling on the raking plate of thepelletizing machine, which is put in slowrotation. Thanks to the raking position ofthe plate and to the material moving, thegreater parts get to the surface while thesmaller parts pass to the lower beds.As soon as the plate is full of pellets (already formed), these pass over its rim and reach thedischarge chute.The system includes also a hopper to be located underneath the pelletizing machine anddesigned to receive and store the pellets; the hopper is fitted with sliding door for pellet dischargeon trucks; the sliding door is driven by a hydraulic mechanism fed by a dedicated power pack. CVS QUALITY MANAGEMENT QUALITY IS NOT ONLY OUR POLICY BUT OUR PHILOSOPHY
  20. 20. CVS GENERAL POLICY WE BELIEVE OUR KNOWLEDGE WE FEEL OURSELVES IN THE CORE OF STEEL FTP REFERENCES Plant capacity Year ofNr. Customer Country Location/site Technology start-up (m3/h)1 NIKSIC Montenegro Niksic 1.200.000 Pulse-jet FF 20092 BILECIK DEMIR CELIK Turkey Bilecik 500.000 Pulse-jet FF 20093 TOSCELIK Turkey Iskenderun 2.300.000 Pulse-jet FF 20094 ENERGOMASSPETSTAL Ukrain Kramatorsk 1.000.000 Pulse-jet FF 20095 SOCIETE UNIVERS ACIER Morocco Casablanca 2.000.000 Pulse-jet FF 20096 Egypt Alexandria 1.400.000 Reverse-air FF 2009 ALEZZ STEEL AL DEKHILIA7 TAYBAH STEEL CO Egypt Al Mansura 600.000 Pulse-jet FF 20088 COJSCO Jordan Amman 600.000 Pulse-jet FF 20069 YESILYURT DEMIR CELIK AS Turkey Samsun 2.000.000 Pulse-jet FF 200610 CER ÇEL K ENDÜSTR A. . Turkey Izmir 1.200.000 Pulse-jet FF 200611 JORDAN IRON & STEEL CO. Jordan Amman 150.000 Pulse-jet FF 200512 JORDAN IRON & STEEL CO. Jordan Amman 150.000 Pulse-jet FF 200513 NURSAN METALURJI AS Turkey Iskenderun 1.000.000 Pulse-jet FF 200514 CER METAL AS Turkey Izmir 1.500.000 Pulse-jet FF 2005
  21. 21. Thank You For Your Patience Makina. Company Presentation