CVS MAKINA - Company Presentation




      -Design
-Manufacturing                                  Offices:
    - Erectio...
CVS MAKINA - Company Presentation



                    CVS provides plants & equipment for minimills,
                  ...
MELTSHOP DESIGN
From Water Cooled Panels to complete Electric Arc Furnaces, from Ladles to complete
Ladle Furnaces, from T...
CVS - EAF
      Design Main Objective

Low production costs

Higher process flexibility.

Increasing productivity
while im...
CVS - EAF
    Chemical Energy System Concept


      CVS has special oxy-burner system for higher productivity

      The ...
CVS - EAF
    Burner Positioning Inside Furnace




  The lance manipulator for the Electric Arc Furnace is primarily desi...
CVS - EAF
    Slag Foaming


                                                 Foaming slag is used to increase the
       ...
CVS - EAF
  Panel Design Example




CVS have big experience for manufacturing of Furnace panels made of copper and
steel....
CVS - EAF
Typical 3-D View




CVS - EAF
Roof Lifting Operation




                         CVS special design of Roof Li...
CVS - E.A.F.
Auxiliaries




CVS - E.A.F.
Auxiliaries

                 Scrap Bucket
               BucketTransfer Car
   ...
CVS - SECONDARY METALLURGY
LF. Concept

                                           The operation executed at the ladle fur...
CVS - SECONDARY METALLURGY
    LF Design Advantageous
    The Ladle Furnace is conceived for reheating the steel in the la...
CVS - SECONDARY METALLURGY
      VD / VOD Plant
  PURPOSE
     • H removal
                                             DE...
CVS - SECONDARY METALLURGY
    VD / VOD Plant
Sulphur Removal

The final sulphur content of a heat depends on the pressure...
CVS - SECONDARY METALLURGY
   VD / VOD Plant
PROCESS                                 COST FOR REMOVING C IN EAF AND VOD
- ...
CVS - SECONDARY METALLURGY
      Ladle Inert Gas Use

                                                  Homogenisation of ...
CVS - Liquid Steel Auxiliaries
   Ladle Emergency Stirrer Lance




This gas stirring system is designed to feed inert gas...
CVS - Liquid Steel Auxiliaries
Ladle Preheaters / Driers




CVS - CCM
Design Concept
CVS - CCM
   Design Concept

CCM can be designed to produce square billets in the sections between 100 to 160
mm2, and blo...
CVS - CCM
      Typical Sectional View




      CVS - CCM
      Equipments

-Ladle Turrets
-Tudish
-Tundish Car
-Ladle Ca...
CVS - CCM
     Ladle Turret
                                 Serving to support the teeming ladle and adjust
             ...
CVS - CCM
      Tundishes




-Delta Shape
- High Residence Time
- Better Inclusion Flotation
- High Tundish Life
- Adapta...
CVS - CCM
    Mould Oscillation
Design Features

- Heavy-duty design
- Sized to support the mould housings assembly
- Desi...
CVS - CCM
      Withdrawal and Straightener




      CVS - CCM
      Dummy Bar




- Rigid design

-Safe operation

-Fast...
CVS - CCM
      Pinch Rolls




      CVS - CCM
      Lateral Transfer System




Designed to move the billets from the
el...
CVS - CCM
     Cooling Bed




The bed is composed by two frames having a
set of mounted blades: one frame is fixed
while ...
CVS - SCRAP BUCKET PRESS
   WHY TO CHOOSE


 - Can be installed on any type scrap
 bucket

 - Lowest Investment Cost

 - E...
CVS - SCRAP BUCKET PRESS
 CVS ADVANTAGES


-Shorter tap-to-tap time

The possibility of a higher scrap
density allows the ...
CVS - SCRAP SHEAR


The design of the CVS press shears is based on the concept with cylindric guides for the
shear head en...
CVS -
    Scrap preheating Systems
Preheating of scrap by utilizing sensible heat of exhaust gas emitted from an EAF have
...
CVS -
    Outline for CVS Scrap preheating Systems

•Heat energy contained in a gas evacuated from an EAF accounts for 15 ...
CVS -
     Carbon Handling System




 Carbon Handling Cost: Less than 30 USD/ton (depending on unit price of
consumable i...
CVS - FTP
      Design Concept




                             FTP DESIGN
From EAF Roof Elbow to Stack, CVS provides comp...
CVS - FTP
    Design Concept

  CVS designs FTP to collect, suck and treat the primary and secondary emissions
  generated...
CVS - FTP
Typical Filter Unit




CVS - FTP
Natural Coolers

        Natural (Hair Pin) Coolers
CVS - FTP
Stack




CVS - FTP
Other Equipments




     Canoppy Hood




                    Pelletizer
CVS -
Converter Off-Gas System

                           WE FOLLOW LAST TECHNOLOGIES
                           WHEN WE ...
CVS -
      Material Handling System

Spare Parts For MHS

-Conveyor bands
-Impact idlers
-Return idlers
-Drive pulleys
-T...
CVS - DRI Continuous Feeding System




It is possible to charge HBI up to 30% without continuous feeding, and up to 100%
...
CVS - Slag Processing System

Slag has been recycled and effectively used as a base coarse material (road bed
material). N...
CVS - Water Treatment Plant
    Typical Equipment




    CVS - Water Treatment Plant
    Design Scope

Scope of services:...
CVS - Water Treatment Plant
    Design Concept

  In the modern metallurgical industry, efficient water management is not ...
CVS -
Piping and Erection for Oxygen Plant




CVS -
Piping and Erection for Oxygen Plant
CVS - AUTOMATION
EAF – Arc Regulation System
                                  Arc Regulation system (ARS) for
           ...
CVS - AUTOMATION
CCM – CASTING EQUIPMENTS




CVS - AUTOMATION
FTP – COMBUSTION CHAMBER
ROLLING MILL DESIGN

From Bar mill to Section Mill, From Chimney to complete Reheating Furnaces, from
Roll Stands and wate...
CVS - ROLLING MILL
      Rolling Mill Turnkey Solution

• All the rolling mill stands are
individually driven by motors

•...
CVS - ROLLING MILL
     Re-heating Furnace
                                         - up to 130 tph nominal capacity
     ...
CVS - ROLLING MILL
Stands




CVS - ROLLING MILL
Typical Loopers
CVS - ROLLING MILL
Typical Shears




CVS - ROLLING MILL
Typical Binding Machines
CVS - ROLLING MILL
   Rolling Mill Cooling Bed and Packing




   CVS -
   Designing General Layout
The design considers l...
CVS -
    Optimised Process
We lay the foundation for optimized processes with proven, leading products
worldwide, includi...
CVS -
      Erection and Site Management

Steel Structure:

Project management of engineering companies and fabrication sh...
CVS -
    Erection and Site Management
                                         Erection engineering & site management

  ...
CVS -
    Erection and Site Management

Main benefits:

Experienced engineers, site managers and supervisors with a well-f...
CVS -
TOSCELIK PROJECT




CVS -
NURSAN EAF PROJECT

                     NURSAN holding is one of the leader
            ...
CVS -
   NURSAN EAF PROJECT

Furnace has reached 35 heats/day
average production thanks to co-
operative work between CVS ...
INNOVATION




          We believe it all starts at the
                 drawing table

  WE INVEST IN RESEARCH AND DEVEL...
DESIGN & ENGINEERING




                     Our people are the most
                     important assets at CVS




CVS...
CVS -
 GENERAL POLICY

     WE BELIEVE OUR KNOWLEDGE




WE FEEL OURSELVES IN THE CORE OF STEEL




REFERENCES


         ...
REFERENCES


                              EUROPE - 2

             SOVEL                             GREECE
             ...
REFERENCES


                                                MIDDLE EAST - 1
                                   IRAN ALLOY...
REFERENCES


                       TURKEY              ASIL CELIK            TURKEY
                                     ...
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  1. 1. 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 info@cvs.com.tr www.cvs.com.tr
  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. MELTSHOP DESIGN From Water Cooled Panels to complete Electric Arc Furnaces, from Ladles to complete Ladle Furnaces, from Tundishes to complete Continuous Casting Machines, from Ducts to complete Fume Treatment Systems and from Engineering Services to Turn-Key Plants, CVS offers economically viable solutions at European standards. CVS Makina. Company Presentation CVS - E.A.F. Design Concept • CVS has more than 50 Electric Arc Furnaces supplied worldwide • Furnace size from 12 to 180 tapped steel • Some EAF futures: – AC type – EBT tapping system – conductive or traditional electrode arms – original roof lifting design – full platform & split shell design
  4. 4. CVS - EAF Design Main Objective Low production costs Higher process flexibility. Increasing productivity while improving energy efficiency. mproving the quality of the finished product. Meet environmental requirements at a minimum cost. Better coordination of process/environmental requirements CVS - E.A.F. Design Benefits Gantry design for self-supporting furnace roof Prismatic roller-guide system for electrode masts High-current-conducting electrode arms in copper-clad box design State-of-the-art electrode control system Split-shell design Copper or combi-panels with high-speed cooling water flow Oxygen and carbon injection All bottom tapping systems EBT, EO-EBT, RBT, OBT) Special hot-metal charging facilities Continuous DRI/HBI feeding systems Main benefits Increased productivity due to shortest melting and idle times High power input (up to 1 MVA/t) High-impedance furnace Arc voltage up to 1,500 V Proven low-consumption values energy, electrodes, refractories, etc.) Low tapping temperatures and minimum slag carry-over Minimum maintenance with the use of heavy mill-type components Highest flexibility with respect to charge materials
  5. 5. CVS - EAF Chemical Energy System Concept CVS has special oxy-burner system for higher productivity The injection system consists of a set of jet burners installed on the EAF shell. The jet burners are supersonic oxygen injectors combined with a hydrocarbon burner, all in the same housing. Three jet burners are installed in the upper shell’s side wall, while the forth one is located in the EBT area. The functions of the injection system are : decarburization of the steel bath thermal energy input formation of foaming slag reduced need of charge carbon with the scrap the thermal energy is efficiently transferred to the bath with less fuel, lower off- gas temperature and much better control of CO emissions. CVS - EAF Burner Design Concept The location and the direction of the burners are determined to reduce the cold spots effect generated by the three-phase arc of the furnace, thus obtaining an even and faster melting. • Higher burner efficiency (cleaner walls, reduction of electric energy consumption) • Higher supersonic oxygen efficiency (reduction of electrode consumption and increase of refractory delta life) • Higher burner power (up to 8 MW burner and 4000 Nm3/h of supersonic oxygen) • Carbon injection in the slag (CH4 + N2 cooled) or above the slag (air cooled)
  6. 6. CVS - EAF Burner Positioning Inside Furnace The lance manipulator for the Electric Arc Furnace is primarily designed for safe oxygen injection. As well, solid materials like Carbon can be given from burner case. The Carbon injection in the bath have demonstrated of outmost importance to work with proper foaming of the slag and to obtain recarburisation of liquid steel bath if required to control bath composition. CVS - EAF Burner Positioning Inside Furnace • Very low installation in water cooled copper box • Refractory saving by cooling block • Long life (8-18 months) • Fast substitution time • Flame shape control • De-Luxe gas valve stand • Improve Metallic Yield • Very flexible automation
  7. 7. CVS - EAF Slag Foaming Foaming slag is used to increase the thermal efficiency of the furnace during the refining period, when the side walls are fully exposed to the arc radiation. A foaming slag will rise and cover the electric arcs, thus permitting the use of a high tap setting without increasing the thermal load on the furnace walls. In addition, an electrical arc covered by a foaming slag will have a higher efficiency in transferring the energy into the steel phase. CVS - Slag Foaming Slag foaming is obtained by injecting oxygen into the liquid steel, where mainly iron is oxidized according to the reaction: O2 + 2 Fe = 2 (FeO) Carbon powder is then injected simultaneously into the slag phase where iron oxide is reduced. (FeO) + C = Fe + CO (g) The resulting CO gas is a critical component in order to obtain a foaming slag.
  8. 8. CVS - EAF Panel Design Example CVS have big experience for manufacturing of Furnace panels made of copper and steel. Special testing methods is applied before shipment. CVS - EAF Typical 3-D View
  9. 9. CVS - EAF Typical 3-D View CVS - EAF Roof Lifting Operation CVS special design of Roof Lifting system yields for easy and safe operation.
  10. 10. CVS - E.A.F. Auxiliaries CVS - E.A.F. Auxiliaries Scrap Bucket BucketTransfer Car Orange Grabs
  11. 11. CVS - SECONDARY METALLURGY LF. Concept The operation executed at the ladle furnace is an essential part of the secondary metallurgy treatment, such as refining, adjustment of liquid steel temperature and chemical composition with the target to increase quality of steel. CVS - SECONDARY METALLURGY LF. Advantages The advantages of a ladle furnace can be defined as follows : •Saving of ferroalloy •Saving of energy •Increase productivity •Decreasing refining time of EAF •Decreasing tapping temperature at EAF •Precise temperature control •Improved of inclusions, cleanliness of the steel •Possibilities of wrong analysis limited
  12. 12. CVS - SECONDARY METALLURGY LF Design Advantageous The Ladle Furnace is conceived for reheating the steel in the ladle placed on a ladle car and will be designed and built according to the most modern techniques in the field and will be in particular provided with: Water-cooled secondary circuit and water cooled flexible cables Water-cooled ladle roof equipped with indirect fume collecting hood to reduce steel oxidation Roof lifting mechanism via hydraulic cylinder Electrode arms with reduced electrode pitch diameter Water-cooled secondary circuit and water cooled flexible cables Electro-hydraulic electrode regulation CVS - SECONDARY METALLURGY VD / VOD Plant The purpose of secondary metallurgical steel treatment under vacuum conditions is to produce high-purity steel having following properties: low content of harmful elements such as sulphur, phosphorus, trace elements and/or carbon, lowering of oxygen, nitrogen and hydrogen gases dissolved in the steel, as well as major improvements of steel purity, including shape control of non-metallic inclusions.
  13. 13. CVS - SECONDARY METALLURGY VD / VOD Plant PURPOSE • H removal DESIGN FEATURES • N removal • S removal • Dimensioning of vacuum tank • C removal (VOD) • Vacuum hopper • Dust separator RESULTS • H contents < 1 ppm • N contents -30/50 % • S contents -80/95 % • C contents < 20 ppm PROCESS •Temperature loss during vacuum treatment CVS - SECONDARY METALLURGY VD / VOD Plant Hydrogen Removal The final hydrogen content of a heat depends on the pressure of vacuum vessel, the amount of the purging gas and the CO-gas development. Even fully killed heats can be treated due to intensive degassing supported by lift gas. For lowest hydrogen levels the pressure must be lower than 1 mbar with according treatment times of 15 - 20 min depending on the starting level. Nitrogen Removal Even in VD-Plants nitrogen removal is preferably carried out. Having low sulphur and oxygen levels this process as well requires low vacuum levels with less than 1mbar for approx. 15 - 20 min. Argon is purged by the porous plugs from the ladle bottom with approx. 10 Nl/(min, t steel).
  14. 14. CVS - SECONDARY METALLURGY VD / VOD Plant Sulphur Removal The final sulphur content of a heat depends on the pressure of vacuum vessel, the amount of the purging gas and the amount of synthetic slag added prior to vacuum treatment start. The EAF furnace slag has to be reduced during tapping to values below or equal to 5 kg/t Steel. For low sulphur levels the pressure must be lower than 1 mbar with according treatment times of 15 - 20 min depending on the starting sulphur level. Argon purging by the porous plug from the ladle bottom with approx. 10 Nl/(min, t steel) has to be ensured. Light Treatment (Deoxidation) The liquid steel will be tapped unkilled or semi-killed from the EAF and partly deoxidised in the VD-plant. The deoxidation will occur due to the CO-development by natural decarburisation. The pressure range depends on the C-O equilibrium and is about 40 - 200 mbar. After 10 - 12 min treatment the final deoxidation will be carried out with Al or others. Thus large amounts of deoxidation agents can be saved by light treatment. CVS - SECONDARY METALLURGY VD / VOD Steam Ejector Pumps
  15. 15. CVS - SECONDARY METALLURGY VD / VOD Plant PROCESS COST FOR REMOVING C IN EAF AND VOD - Modelling of the VOD process - Optimisation EAF-VOD OPTIMUM RANGE - Slag reduction EAF COST - Desulphurisation VOD VOD PROCESS CONTROL -Calculation functions - Thermodynamic model - Example of oxygen blowing 0 0.5 1.0 CARBON CONTENT THERMODYNAMICSC - removal at low pCO and high temp ( fCr * %Cr )2 * pCO3 * 10( 40536/ T 25.63) 3C Cr2O3 3CO 2Cr %C 3 aCr2O3 * fC 3 CVS - SECONDARY METALLURGY VD / VOD Plant
  16. 16. CVS - SECONDARY METALLURGY Ladle Inert Gas Use Homogenisation of The Bath Temperature Homogenisation of the Bath Chemical Composition Better Mixing Between Steel and Slags Better yield of additives (ferroalloys) More Clean steel a. Refractory material on the ladle bottom b. Porous plate c. Porous refractory insert d. Locking equipment e. Gas inlet CVS - Liquid Steel Auxiliaries Ladle and Ladle Cars
  17. 17. CVS - Liquid Steel Auxiliaries Ladle Emergency Stirrer Lance This gas stirring system is designed to feed inert gas through a refractory lance for emergency stirring if the porous plug does not work properly. The refractory lance is held and plunged into the steel bath by a structure adjacent to the ladle roof. CVS - Liquid Steel Auxiliaries Ladle Preheaters / Driers Ladle pre-heater/drier consists of a circular, concave lid a centrally located fuel-air burner. The burner creates a high-velocity, extended flame, which brings the thermal energy down to the ladle bottom. The combustion air is generated by a centrifugal fan located in a protected position in the burner stand and led via the cover suspension arm to the burner. The hydraulic power for lid movements is provided by an independent hydraulic power pack. The burner is directly ignited by means of a high voltage device after automatic purging of the combustion chamber.
  18. 18. CVS - Liquid Steel Auxiliaries Ladle Preheaters / Driers CVS - CCM Design Concept
  19. 19. CVS - CCM Design Concept CCM can be designed to produce square billets in the sections between 100 to 160 mm2, and blooms between 180 to 260 mm2. Special designs for beam blank and round sections between 160 to 440 mm can be done. Radius of 5-12 meter and mould length of 750-1000 mm can be designed according to project requirement. For some special casting, vertical continuous casting application can be considered. The CCM can be fitted with up to eight casting strands in order to satisfy the production schedule given by the EAF. According to customer request, CCM can be equipped with the necessary modern equipment to produce high quality casted products, such as tundish of delta type to reduce inclusions in the mould, long copper tube to improve primary cooling on the billet surface, automatic mould level control system, high casting radius to reduce stress during unbending, secondary spray cooling divided in three zone for a better cooling effect and control, walking beam cooling bed for the straightening of the long billets. CVS - CCM Typical Sectional View
  20. 20. CVS - CCM Typical Sectional View CVS - CCM Equipments -Ladle Turrets -Tudish -Tundish Car -Ladle Car -Moulds -Mould and Strand Stirrers -Automatic Mould Level Control -Foot Rolls -Spray bending sector -Mould Oscillating Tables -Tudish Preheater -Rigid Dummy Bars -Withdrawal and straighining unit -Rigid Dummy Bar Parking Device -Intermediate Roller Table -Billet Side Transfer -Collecting Table -Cooling Bed
  21. 21. CVS - CCM Ladle Turret Serving to support the teeming ladle and adjust it to casting position. Design for handling up to two full teeming ladles. Weighig Load-cells Emergency Turret Rotation Different Designs Ladle Car Ladle Rotation Arm Liftible Ladle Turret Independent Arm Ladle Turret CVS - CCM Tundish Car Different Designs Serving to support the tundish and adjust it to casting position. Cantilever Type Rail Type Quick nozzle changer system Semi-cantilever Type Liftable Type Adaptable to stopper rod mechanism Weighig Load-cells Emergency Translation via electric motor
  22. 22. CVS - CCM Tundishes -Delta Shape - High Residence Time - Better Inclusion Flotation - High Tundish Life - Adaptable to close casting CVS - CCM Tundish Pre-heaters
  23. 23. CVS - CCM Mould Oscillation Design Features - Heavy-duty design - Sized to support the mould housings assembly - Designed to permit mould oscillation along the casting radius - Adjustable stroke, frequency and negative strip time. - Easy access to the mechanism itself - Protected from the cooling chamber environment. - Allowing for fast and precise positioning. Different Designs Electro-mechanical Hydraulic Air spring Mechanical Spring CVS - CCM Secondary Cooling -Heat resistant concrete walls - Modular structure - Steel doors and walkways allow maintenance access to the sprayers and to the bow guide. -Visual inspection openings. -Steam extraction fan. -Automatic Control of Spray Water Quantity - Completelly water spray nozzle or air mist design - Guiding rollers
  24. 24. CVS - CCM Withdrawal and Straightener CVS - CCM Dummy Bar - Rigid design -Safe operation -Faster restranding of strand - Quick automatic disconnecting operation.
  25. 25. CVS - CCM Pinch Rolls CVS - CCM Lateral Transfer System Designed to move the billets from the elevated position above the discharge roller table to the cooling bed area. The transfer system is composed by a bridge beam that spans over the removal area and translates across it.
  26. 26. CVS - CCM Cooling Bed The bed is composed by two frames having a set of mounted blades: one frame is fixed while the other is alternately moved in a vertical and horizontal direction by two sets of hydraulic cylinders. During its movement, the movable frame advances the billets along the fixed frame thus allowing an uniform cooling of each bar. CVS SCRAP BUCKET PRESS UP TO 60 % INCREASE IN THE SCRAP DENSITY IN SCRAP BUCKET THANKS TO THE HYDRAULIC FORCE UP TO 250 TON LOAD.
  27. 27. CVS - SCRAP BUCKET PRESS WHY TO CHOOSE - Can be installed on any type scrap bucket - Lowest Investment Cost - Easiest Installation - Consists of a large vertical pressure block that compresses the scrap within the bucket. - Since it is totally protected, it is practically maintenance free. - High speed and fully automated design. CVS - SCRAP BUCKET PRESS FEATURES - All safety features can be provided as per European Norms. - Rigorously tested prior to the delivery - Load up to 250 ton - Heavy and Rigid construction - Convenient and Safe Operation - Giving Flexibility for Scrap Preparation
  28. 28. CVS - SCRAP BUCKET PRESS CVS ADVANTAGES -Shorter tap-to-tap time The possibility of a higher scrap density allows the power-off time to be shortened by as much as 1 bucket less charge. -Improved productivity -Thanks to a faster operation, the power off time can be reduced by up to 20%. -It's possible to achieve an overall up to 10 % increase in productivity. CVS - SCRAP BUCKET PRESS PRESS OPERATION PRESS OPERATION PARK POSITION
  29. 29. CVS - SCRAP SHEAR The design of the CVS press shears is based on the concept with cylindric guides for the shear head ensuring a precise cut between the upper and lower blades. The shear is build within a robust, twist resistant welded construction allowing installation directly onto concrete without anchorage and therefore having low foundation costs. The shear is equipped with a hydraulically operated filling box which allows charging of the shear during production. This design decreases the charging time and increases the productivity. The machined pressing box ensures the precise movement of the compactors as well as fast and stick free pre-compaction of bulky scrap. The extra long vertical holder guides allow the scrap that has been pre-compacted by the side-compactor to be pressed against the lowered vertical holder, allowing bales can be produced as well. CVS - SCRAP SHEAR
  30. 30. CVS - Scrap preheating Systems Preheating of scrap by utilizing sensible heat of exhaust gas emitted from an EAF have been investigated for many years in many plants.As a result of scrap preheating, not only the electric power and time required for steelmaking but electrode and refractory consumption has decreased. Condition of temperature on the preheating system: - Inlet temperature of preheater: approx. 8000C – 2000C - Outlet tempearture of preheater: approx. 2500C – 500C - Temperature of preheated scrap: approx. 4000C – 1000C - Temperature at combustion chamber inlet widely varies between 12000C to 3000C according to the time and conditions of the steelmaking stages. Outlet temperatures of the preheating system stays at low temperatures which indicates that heat absorption by scrap is fully accomplished. Temperature of scrap indicates the difference between upper and lower parts of the charging bucket. Main Profit: Preheated scrap average temperature is between 150°C - 200°C The amount of energy saving is 20 – 30 kwh/ton in practice. CVS - Scrap preheating Systems -Easy Solution -Low Investment Cost -Better Operation -Adaptable for Existing Automation -No dioxin - Maintenance Friendly
  31. 31. CVS - Outline for CVS Scrap preheating Systems •Heat energy contained in a gas evacuated from an EAF accounts for 15 to 20 % of the total energy used in EAF steel making process and that is 100 – 150 kwh/ton. •CVS scrap pre-heater is a system which utilizes this heat energy to heat scrap in a bucket before charged into an EAF and thus contributes towards energy saving. Gas evacuated from the EAF is led to a combustion chamber through a suction duct together with air induced through gap between EAF elbow and sliding sleeve duct to burn CO contained in the gas, a part of this burned gas is introduced in to the bucket placed at the scrap to heat scrap. After passing the bucket, the gas is returned to the combustion chamber by a preheating fan. This is called Recycle Flow in the system. When scrap does not contain oil and other combustibles, the gas after preheating my be sent to the duct collector. This is called Direct Flow in the system. For Recycle flow, combustibles contained in the gas after preheating is burned by mixing with the gas from the EAF. This enables to eliminate an air pollution after dust collector. CVS - Outline for CVS Scrap preheating Systems It is important to minimize gas leakage in a preheating line. For this purpose, special sealing devices are provided between hood pipe and inlet duct, hood and scrap bucket top edge, bucket cylinder and clamp shells. By use of the adequate sealing devices, air introduced into the scrap pre-heater is very small. By provision of preheating fan, existing fume treatment plant can employ the scrap pre- heater without modification. As the system is fully automatically operated, this system does not require additional worker. EAF operation will not be interrupted even if the preheating system run into a trouble. Recycling method of preheating system can be controlled separately from dust collector system. Proper adjustment of the preheating temperature prevents the scrap bucket from being deformed.
  32. 32. CVS - Carbon Handling System Carbon Handling Cost: Less than 30 USD/ton (depending on unit price of consumable items) 70 USD/ton saving from operation Investment Pay-Back Maximum 10-months CVS - Carbon Handling System Design Features Design Advantages Up to 5.000 ton/month Starting Carbon Low dust Size: 0-100 mm Fast Pay-back Humidity: Up to %25 Minimum Investment End Product: Maintenance Free Humidity: Less than 1 % Low operation Cost 3-8 mm Carbon (10-40 %) Higher productivity 0-3 mm Carbon (30-80 %) Safe Operation Dust: Less than 6 % Fully-automatic Energy Consumption: Adaptable for Less than 8 kWh/ton C automatic feeding NG Consumption: Less than 30 Nm3/ton C
  33. 33. CVS - FTP Design Concept FTP DESIGN From EAF Roof Elbow to Stack, CVS provides complete Fume Treatment Plants with engineering, design, manufacturing and installation. Design considers also LF, MHS, canoppy and other dust emitting points by the goal of ZERO DUST EMITION to environment. CVS offers economically viable solutions at European standards. CVS - FTP Design Focus -Water Cooled Ducts -Combustion Chamber Panels -Elbows -Radiant Ducts -Water Cooled Dampers -Filter Bags -Damper Actuators -Pressure Tank For Filter -Pulse jet valves Reliability Reduced maintenance requirements Reduced operating cost (electrical energy, compressed air) Low residual dust content at stack Low noise emission technology Environment Friendly
  34. 34. CVS - FTP Design Concept CVS designs FTP to collect, suck and treat the primary and secondary emissions generated by the EAF, the primary emission generated by the LF and the emission emitted by the Material Handling System. The dedusting system consists of a set of fume collection points and a set of ducting lines (water-cooled or radiant type), which convey the various emissions to the bag filter already under implementation. CVS designs FTP with the following aim: •minimum operation and maintenance costs; •optimal utilization of spaces inside / outside the meltshop; •automatic operation, “hands-off” type; and twenty-four hours operation. CVS - FTP Design Concept Design considers following working profile: Melting phase •EAF in melting phase (roof closed, primary fumes suction line open); •Suction from the canopy hood to provide meltshop ventilation and primary fumes cooling; •LF in heating phase; •MHS in operation. Charging/Tapping phase •EAF in charging/tapping phase (roof open, primary fumes suction line closed); •Suction from the canopy hood; •LF in heating phase; •MHS in operation.
  35. 35. CVS - FTP Typical Filter Unit CVS - FTP Natural Coolers Natural (Hair Pin) Coolers
  36. 36. CVS - FTP Stack CVS - FTP Other Equipments Canoppy Hood Pelletizer
  37. 37. CVS - Converter Off-Gas System WE FOLLOW LAST TECHNOLOGIES WHEN WE MANUFACTURE OFF GAS SYSTEMS CVS - Converter Off-Gas System
  38. 38. CVS - Material Handling System Spare Parts For MHS -Conveyor bands -Impact idlers -Return idlers -Drive pulleys -Tail pulley -Bend pulley -Belt scraper -Electrical Motors -Couplings -Drive reducer CVS - MHS Design Concept The plant is divided into three main parts: a) Equipment for Ferro-alloys and additives storage from receiving hoppers to the bins battery b) Equipment for Ferro-alloys and additives extraction, dosing and weighing, transport and charging into furnace, ladle in tapping position and L.F. c) Equipment for Carbon and lime extraction, dosing and weighing, transport and charging into scrap buckets.
  39. 39. CVS - DRI Continuous Feeding System It is possible to charge HBI up to 30% without continuous feeding, and up to 100% using top feeding. Slag control, feeding rate and power input are the key factors in continuous charging procedures. CVS - DRI Continuous Feeding System Continuous feeding of HBI is typically performed to: Physical requirements for continuous feeding of HBI and • To eliminate one or more buckets from the charge, DRI: thereby reducing heat losses and power off time • Allow high rates of HBI use. • HBI must be present as single • Boost productivity and reduce heat losses by briquettes or pieces to prevent combining melting and refining. jamming on conveyor belts and transfers, • A maximum briquette dimension that is less than 50% of the minimum hopper opening, • Low abrasion index to prevent excessive dusting and yield loss.
  40. 40. CVS - Slag Processing System Slag has been recycled and effectively used as a base coarse material (road bed material). Now, it is also possible to use soil-improvement material (for hardening of soft ground). Primary and secondary jaw crushers are designed to crush all kinds of stone regardless the hardness and abrasives. They are the most advanced jaw crushers available with hydraulic settings, central lubrication, high performance, efficiency and capacities. CVS - Slag Processing System -Removal of slag residue from refined iron 0 - 8 mm -Metal recovery from slag and waste incineration ash -Production of concentrates with a high metal content in first step -Hydraulic sizing for the removal of fine components at cut - points 1 - 8 mm -Removal of filler material from the fine fraction prior to the use of next step separators -Reduction of crusher feed by pre- separation off non-metallic slags -Selective comminution of metal-slag composites, special types of crusher are available
  41. 41. CVS - Water Treatment Plant Typical Equipment CVS - Water Treatment Plant Design Scope Scope of services: Utilities and storage systems Water supply and treatment plants Scale water and muddy water treatment plants Project planning, feasibility studies and project management Monitoring activities for installation as well as commissioning and plant operation Engineering and project management for piping systems
  42. 42. CVS - Water Treatment Plant Design Concept In the modern metallurgical industry, efficient water management is not only a means to an end, but a guarantee for economic and ecological process flows. Perfect integration into the entire system is vital to ensure competitiveness in the future. The implementation is always adapted to local legal requirements, environmental protection conditions and customer standards. Modern water management is mainly affected by three factors: quality of the make-up water, climatic conditions legal requirements. These are partially determined by varying regional conditions. Thanks to our many years of experience in the various regions of the world and our comprehensive process knowledge in plant construction, we’re able to professionally incorporate these localized, varying factors into the plant design. CVS - Water Treatment Plant Design Advantageous Main benefits: All systems are optimally integrated into the production plants Single-source responsibility is ensured for the entire metallurgical process Compliance with all environmentrelevant requirements is guaranteed A total solution provider as well as a supplier of individual products and components meets all of your requirements
  43. 43. CVS - Piping and Erection for Oxygen Plant CVS - Piping and Erection for Oxygen Plant
  44. 44. CVS - AUTOMATION EAF – Arc Regulation System Arc Regulation system (ARS) for EAF applications is the latest stage of development which using PC based Windows XP operating system. Using a special algorithm following benefits can be offered to customer; - Fast adjustment of arc length, - Fast response and fast and stable control, - Minimizing of power consumption, - Minimizing of flicker effects due to regulation quality, - Minimizing of electrode and refractory consumption. CVS - AUTOMATION EAF – Voltage & Current MeasuringSystem Actual voltage and current of furnace are read by special analog/digital converter card installed on the PC. Generally the current of primary side of the transformer is converted in order to make the furnace main PLC panel read these current values. The conversion is made by current transformer of transformer and the matching transformer (generally supplied by transformer manufacturer). The outputs of the current transducer in the furnace main PLC panel are inputs for A/D converter card on PC.
  45. 45. CVS - AUTOMATION CCM – CASTING EQUIPMENTS CVS - AUTOMATION FTP – COMBUSTION CHAMBER
  46. 46. ROLLING MILL DESIGN From Bar mill to Section Mill, From Chimney to complete Reheating Furnaces, from Roll Stands and water quenching system to complete Rolling Mill Train, from Cooling Bed Area to Handling Area, from Flying Shears to Cold Shears, Full Automation System and from Engineering Services to Turn-Key Plants, CVS offers economically viable solutions at European standards. CVS Makina. Company Presentation CVS - ROLLING MILL Rolling Mill Turnkey Solution • All mechanical equipment incorporates the latest known and proven technology. • All mill stands are housingless series, which are known worldwide for their rigidity and ease of maintenance. • The stands can be used for producing all grades of steel up to and including stainless high speed and high alloy steel. • Special "robots" are used for quick roll changing thus reducing the requirement for costly spares and stand by equipment.
  47. 47. CVS - ROLLING MILL Rolling Mill Turnkey Solution • All the rolling mill stands are individually driven by motors • Inter-stands tension of the bar can be controlled to acceptable limit. • Improved quality of the finished product • Reduced risk of scrap or cobbled bar. • Flying shear is provided to remove the oversize head of the bar as it progresses down the rolling line. • Maintenance friendly design CVS - ROLLING MILL Equipments -Reheating Furnaces -Gear Boxes -Vertical Stands -Horizantal Stands -Rolls -Shafts -Stand Sliding System -Intermediate Stands -Finish Stands -Crop Flying Shear -Flying Shear -Cooling Bed -Binding Machine -Start-Stop -Lopper -Weighing system -Guides -Cold Shear -Clamping
  48. 48. CVS - ROLLING MILL Re-heating Furnace - up to 130 tph nominal capacity - furnaces complete with charging table and discharge roller table. - Walking heart type, pusher type or walking beam type. - Dual Type Burner application - Design of special emphasis on fuel saving and operational efficiency. - Recuperation, provided to further increase the overall fuel efficiency. - The discharge machine, called kick- off, controlled from the main pulpit. - Minimized the manpower so that only furnace pulpit operator will be responsible for both furnace operation and billet charging. CVS - ROLLING MILL Guides
  49. 49. CVS - ROLLING MILL Stands CVS - ROLLING MILL Typical Loopers
  50. 50. CVS - ROLLING MILL Typical Shears CVS - ROLLING MILL Typical Binding Machines
  51. 51. CVS - ROLLING MILL Rolling Mill Cooling Bed and Packing CVS - Designing General Layout The design considers latest technology in the field of steel plant machinery and equipment. The layout takes full advantage of the rationality of material handling in the plant in order to obtain the following results: •Minimum amount of areas occupied •Optimization of personnel required •Optimization of production times and costs. •Best scrap handling •Future Extension consideration of plant The layout of the meltshop and the location of Auxiliary Plants have been carefully analyzed for best logistics inside the plant like raw materials, semi- products and waste material. Design Focus •Limited investment costs •High quality products •High productivity •Maximum simplicity of operation •Operation reliability •Maximum flexibility to meet various market demands.
  52. 52. CVS - Optimised Process We lay the foundation for optimized processes with proven, leading products worldwide, including mechanical and technological engineering for metal production and rolling as well as process control engineering, drive engineering and power supply. Integrated online and offline process models reflect decades of practical experience and help to ensure reliable, reproducible quality. Our process engineering expertise fuses these products into complete plant solutions that also accommodate the upstream and downstream processes. These solutions are the basis for optimal resource use, minimized waiting times and reduced maintenance and spare parts costs, as well as wide flexibility with respect to raw materials and the resulting products. A further factor for competitive production is the quality of information processing. Production data must be consolidated and compared with planning data to ensure optimal production flow. CVS - Training and Technology Transfer Whenever CVS recieves an order for steelmaking equipment, engineering services and know-how transfer are mutually agreed upon between both parties. Thanks to our experience, there is no question that we know that this is fundamental basis for succesful production equipment. The second step of know-how transfer is an off-site training of customer’s engineers, technicians and skilled workers. The main target of training on the customer’s site is to familiarise their personel with hands-on operation ofthe supplied machines and equipment. The operators and maintenance personel are trained step by step to prepare them for successful operation of the equipment.
  53. 53. CVS - Erection and Site Management Steel Structure: Project management of engineering companies and fabrication shops Structural design engineering including static and dynamic calculations Shop drawings Preparation of tender documents and evaluation of bids Quantity survey for invoicing purposes Fabrication of steel structure Supervision of fabrication Design studies for economic solutions CVS - Erection and Site Management For erection engineering, site management and site monitoring, our professional handling of the site ensures the quality of the plant and guarantees adherence to both the budget and the schedule. In addition, our experts have experience in dealing and working together with people from different cultural groups. With their social sensitivity, motivation and leadership ability, they ensure a perfectly functioning site. On-site health and safety Our staff is well trained with regard to health and safety issues. Compliance with international, local, customer and company regulations is mandatory, and is assessed on a regular basis
  54. 54. CVS - Erection and Site Management Erection engineering & site management Cost estimation for site management and execution of erection Preparation of time schedules for greenfield and brownfield projects Preparation of site organization, site regulations and safety rules Preparation of tender documents for the execution of erection Final accounting of subcontractors Change management Enforcing safety rules and site regulations Follow-up of progress and budget CVS - Erection and Site Management Assuring quality requirements Providing facilities & accommodation Regular coordination with customer Supervision of erection: Checking the completeness of supplies together with the erection contractors Instructions for storage, erection, surveying and testing Securing the timely, proper and professional execution of erection
  55. 55. CVS - Erection and Site Management Main benefits: Experienced engineers, site managers and supervisors with a well-founded and wide range of state-of-the-art experience, as well as cultural awareness are available. Selection of erection contractors is optimized in accordance with the scope of work, local conditions and their experience. Single point coordination of the entire site activities including time scheduling for an optimized erection time, and budget planning, ensures the lowest possible costs and best possible quality. CVS - Turn-key Solution
  56. 56. CVS - TOSCELIK PROJECT CVS - NURSAN EAF PROJECT NURSAN holding is one of the leader company in Turkey, especially in South part of Turkey. Rolling mill plant started production in 1984. After his fast grow, it is decided to make investment for billet production. New meltshop started production in 2003. The same fast grow has been seen thanks to well oriented, expert and dynamic team. In 2008, they decided to increase furnace capacity and signed contract with CVS for high efficiency, environmet-friendly, maintenance free special furnace design.
  57. 57. CVS - NURSAN EAF PROJECT Furnace has reached 35 heats/day average production thanks to co- operative work between CVS and NURSAN technical team during design, assembly and start-up period. CVS - TOSCELIK PROJECT TOSCELIK project is our one of turn key project in Turkey. TOSYALI holding was one of the leader company in Turkey especially in pipe production. They decided to make new meltshop and rolling mill investment for long production and slab production. They awarded CVS for comple turnkey solution. Turnkey Project Covers following Units: • Steel Structure • SVC Unit • 155 ton AC Arc Furnace • Ladle Furnace • 6 strand CCM • Fume Treatment Plant • Water Treatment Plant • Oxygen Plant • Other steel plant facilities
  58. 58. INNOVATION We believe it all starts at the drawing table WE INVEST IN RESEARCH AND DEVELOPMENT FOR PERPETUAL IMPROVEMENT IN INNOVATION DESIGN & ENGINEERING We put our experience and know-how in steel industry behind our products and services
  59. 59. DESIGN & ENGINEERING Our people are the most important assets at CVS CVS - QUALITY MANAGEMENT QUALITY IS NOT ONLY OUR POLICY BUT OUR PHILOSOPHY
  60. 60. CVS - GENERAL POLICY WE BELIEVE OUR KNOWLEDGE WE FEEL OURSELVES IN THE CORE OF STEEL REFERENCES EUROPE - 1 ARCELORMITTAL CARINOX BELGIUM ARCELORMITTAL INDUSTEEL BELGIUM DUFERCO BELGIUM ELLWOOD BELGIUM BH STEEL BOSNIA HERZEGOVINA ARCELORMITTAL DUNKERQUE FRANCE GERLAFINGEN SWITZERLAND BENTELER GERMANY BK SERVICE GERMANY SALZGITTER GERMANY ARCELOR MITTAL HAMBURG GERMANY HALYVOURGIA GREECE HALYVOURGIKI GREECE SIDENOR GREECE SOVEL GREECE
  61. 61. REFERENCES EUROPE - 2 SOVEL GREECE ABS ITALY ALSTOM POWER ITALY ARCEMI ITALY FERRIERE NORD ITALY THYSSEN KRUPP ITALY KOMOTEK BULGARIA KREMIKOVSKI BULGARIA STOMANA BULGARIA ARCELORMITTAL LUXEMBOURG CORUS THE NETHERLANDS THAMESTEEL UNITED KINGDOM NIKSIC MONTENEGRO CMC SISAK CROTIA CELSA UK ENGLAND REFERENCES CIS COUNTRIES ARCELORMITTAL SKOPJE MACEDONIA ARCELOR MITTAL TEMIRTAU KAZAKHISTAN DHT METAL AZERBAIJAN DETAL AZERBAIJAN BAKU POLAT DOKME AZERBAIJAN MAKSTIL MACEDONIA GMZ RUSSIA MMK RUSSIA REVYAKINO RUSSIA GORKY STEEL RUSSIA NOVOROSSMETAL RUSSIA REVYAKINO RUSSIA EMSS UKRAINE JSC DNEPROSPETSSTAL UKRAINE AMK ALCHEVSK UKRAINE MAKAEVKA STEEL WORKS UKRAINE
  62. 62. REFERENCES MIDDLE EAST - 1 IRAN ALLOY STEEL IRAN KHAZAR BILLET IRAN KHORASAN STEEL IRAN MUBAREKEH STEEL IRAN METEOR IRAN PERSIAN FOOLAD IRAN COJSCO JORDAN JORDAN IRON JORDAN UNITED IRON JORDAN SHARQ SOHAR OMMAN NATIONAL DEVELOPMENT CO OMMAN AL HADDAD PALESTINE COPSCO PALESTINE QATAR STEEL QATAR AL RAJHI SAUDI ARABIA AL TUWAIRQI SAUDI ARABIA NATIONAL STEEL SAUDI ARABIA AL WAHABI SYRIA MED STEEL SYRIA REFERENCES MIDDLE EAST-2 AL EZZ GROUP EGYPT ARCO STEEL EGYPT BESHAY STEEL EGYPT EGYPTIAN IRON & STEEL EGYPT SUEZ STEEL EGYPT . TAYBEH STEEL EGYPT SONASID MOROCCO ARCELOR MITTAL ANNABA MOROCCO SOCIETE UNIVERS ACIER MOROCCO HOD METAL ISRAEL YEHUDA STEEL ISRAEL NORTH AMERICA INDUSTRIAS NACIONALES DOMINICAN REPUBLIC CHARTER STEEL USA HOGANAS USA TIMKEN USA
  63. 63. REFERENCES TURKEY ASIL CELIK TURKEY AKDEMIR TURKEY BILECIK D.C. TURKEY CEMTAS TURKEY CER CELIK TURKEY COLAKOGLU TURKEY CUKUROVA TURKEY DEMIRSAN TURKEY DILER TURKEY EKINCILER TURKEY EGE DEMIR CELIK TURKEY ERDEMIR TURKEY HASCELIK TURKEY ICDAS TURKEY ISDEMIR TURKEY IZMIR DEMIR CELIK TURKEY KAPTAN TURKEY KARDEMIR TURKEY KROMAN TURKEY KUMAS TURKEY NURSAN TURKEY SIVAS DEMIR CELIK TURKEY TOSYALI HOLDING TURKEY YESILYURT TURKEY YUCEL BORU TURKEY Thank You For Your Patience www.cvs.com.tr CVS Makina. Company Presentation

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