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Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
Energy optimization at EAF
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Energy optimization at EAF

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DESCRIPTION OF NEW TECHNOLOGIES IN EAF STEELMAKING FOR ENERGY OPTIMISATION.

DESCRIPTION OF NEW TECHNOLOGIES IN EAF STEELMAKING FOR ENERGY OPTIMISATION.

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  • 1. E N E R G Y   O P T I M I Z AT I O N AT   E L E C T R I C   A R C   F U R N A C E S 1INDEX  Who Is CVS  Steel Industry  Steel Industry & Energy  Why The Energy Efficiency Is Important  Classical Methods for Energy Efficiency  New Concepts for Energy Efficiency 2
  • 2. C O M PA N Y   P R O F I L E CVS TURKEY CVS EUROPE CVS MIDDLE EAST CVS CIS Italy‐Udine Egypt‐Cario Ukraine‐Donetsk FROM CONCEPT TO COMMISSIONING Design Manufacturing Erection Training Consultancy Innovation Process DevelopmentCVS POLAND CVS IRAN CVS INDIA CVS S.KOREA CVS SINGAPORE CVS INDONESIA CVS USA CVS GREECE CVS TRADE B.V. Warsaw Tahran Pune Seoul Singapore Jakarta New York Athens Amsterdam 3 info@cvs.com.tr                          www.cvs.com.trC O M PA N Y   P R O F I L E  CVS provides plants & equipments for minimills (Meltshops & Rolling Mills), as well as “turn‐key” solutions in this regard.  CVS covers the complete design and manufacturing activities for green field projects green‐field as well as revamping/upgrading of existing plants and equipments.  CVS manufactures spare parts & components for Meltshops & Rolling Mills & Off‐Gas Systems Off Gas Systems.  CVS provides technical assistance and consulting service to steel production. 4
  • 3. C O M PA N Y   P R O F I L E  CVS headquarter is located in the most sophisticated q p industrial region of Turkey; Gebze (50 km to Istanbul city center), close to many major ports.  Our modern facilities consist of three integrated major‐sized workshops equipped with post‐modern machinery parks and three engineering buildings summing up approx. 100,000 sqm.  CVS workforce is formed by over than 750 specialized staff with a modern machinery park to undertake even th most challenging projects. d t k the t h ll i j t  More than 270 engineers and administrative employees are involved in the design and management of the projects. 5ACTIVITIES 6
  • 4. STEEL INDUSTRYAfter crisis, World Iron & Steel Industry started to growing again.In 2010, all over the world, more than 1 billion 400 million tons/year steel was produced,and it will be increased each year as before crisis. yAccording to rapid growing up in recent years all over the world, new requirements andnew formations to answer these requirements are occured.Steelmaking is always a growing sector and steelmakers are always asking for moreflexible dfl ibl and more easy operation f meltshop units. ti for lt h it 7STEEL INDUSTRY 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010847,670 850,345 904,053 969,992 1,069,082 1,146,686 1,251,196 1,351,289 1,329,123 1,211,461 1,413,596 The crisis of steel market was started in the end of 2008, as all other markets. And it has been continued throughout the entire 2009. In the end of 2009, the effects of crisis was began to pass. And again the market was started to grow up. But something was changed. Maybe the costs are not higher before crisis but profits are lower. Energy and scrap are the biggest cost of meltshops. 8
  • 5. STEEL INDUSTRYToday, investors worldwide are looking and waiting for new signals from steel market tounderstand where to direct and dedicate their money, energy and resources for possiblealternative business. Because of uncertainty in the market, steelmakers are looking formore flexible operation to catch the changing market demands. p g gAccording to requirements of the market, steel production will be increased, and newinvestment will be try to answer.Competition will be even more difficult, and the steelmakers will look new concepts toreduce th steelmaking costs. d the t l ki t 9STEEL INDUSTRY AND ENERGYWhy the energy efficiency is important? Approximately 12% of energy produced all over the world is consumed at Iron & Steel Industry. So we can understand the importance of energy efficiency. With the increasing of steel production studies of to reduce the energy consumption are of steel production, studies of to became important. But, 50% of consumed But 50% of consumed energy is loss due to several reasons is loss reasons. In the end of these studies, the recovered energy will be very high, and the costs can be  reduced with possible new concept i d d ih ibl investments. 10
  • 6. STEEL INDUSTRY AND ENERGY5 main input for meltshops with EAF1. Scrap2. Energy3. Refractoryy4. Ferro Alloys5. ElectrodesTo reduce the scrap cost is limited for steelmakers but they can recude energyconsupmtion themselves.The scrap cost is determined by market. And request of steel production is increasedevery day.Based on this growing, coke, iron ore and scrap requested are increased so much and theirinternational costs will be higher than the past.The difference between product and input price, is determined to the profit of 11steelmakers.STEEL INDUSTRY AND ENERGYThere are a lot of inputs and outputs of EAF.But the most important and can be reduced one is electricity energy. p y gyHow can we reduced the electricity energy consupmtion?With classical methods this is not advantage for the competition because of all important methods,competitors knows to use this energy input.With new concepts, this can be created to make a difference if you can find the rightinvestments. 12
  • 7. CHEMICAL ENERGY In the EAF melting process the chemical energy is playing an important role since production costs and productivity have to be always improved. It is now common practice to use between 30% and 40% of the total energy input to the EAF being supplied through oxy‐fuel burners and oxygen lancing. yg gExothermic reactions are provided veryimportant energy input.At EAF, while the energy inputs are calculated;Total oxygen which blows from burners (burnermode & jet mode) and lance manipulator, totalNG which blows from burners, total C which iscoming from with charge injection and scrap charge, scrap,total removal elements are going into the 13calculations.CHEMICAL ENERGYThe Advantages of the CB system are:‐ Operate the furnace with multipoint oxygen injection that allow a more intensive and/or efficient chemical energy utilization.‐ Operate the furnace with multipoint carbon injection to better foam the slag.‐ Minimise operation with slag door open reducing the energy losses via furnace off gas.f ff‐ Avoid any manual lancing operations.‐ High lifetime and reliability of the equipment.‐ Full process automation Full process automation.The CB system has the following benefits on the furnace performance:‐ Reduced electrical energy requirements, as less energy is lost in the off gases.‐ Better energy and thermal balance inside the furnace.‐ High flexibility and high efficiency on chemical energy utilisation. 14
  • 8. CHEMICAL ENERGYAlong with the main target, the other reasons for using chemical energy for melting are:‐ much greater flexibility of processes with regard to raw materials and energy availability‐ increased productivity while simultaneously improved energy efficiencyThe complete system installed on the furnace enables the following functions:‐ Fuel utilization: the fuel burners are installed onto the cold spots in order to balance the totalenergy input into the furnace on the basis of the process requirements.‐ Steel bath refining: the multipoint oxygen injection allows for fast and homogeneous bathdecarburization and superheating.‐ Slag foaming: the checking of the covering of the bath and the arc by a suitable management ofthe carbon injection injection. yg ; Burner oxygen; ‐ Burner fuel (Natural Gas, LPG, CH4, etc.); ‐ Lance oxygen; ‐ Carbon injection. 15CHEMICAL ENERGYTo reduce the power on time, the electrical energy input to the furnace must be rather aggressive.The correct power program must be used and is designed to balance both electrical and chemical(burner and lance) power inputs. In the early stages of melting a short arc is selected to avoidexcessive damage to the roof panels from arc flare. This slight reduction in the initial power ishowever compensated for by the CB burner‐injector units which are fired very quickly during initialarcing and maximize the energy input to the cold scrap.Slag foaming i extremely iSl f i is t l important if an aggressive arc i t b maintained th t t i is to be i t i d throughout th h t A h t the heat. Asthe scrap level reduces in the furnace and flat bath conditions are approached the height of thefoaming slag must be increased to completely submerge the arc and prevent damage to the watercooled panels panels. 16
  • 9. CHEMICAL ENERGY REMOVAL OF ELEMENTS C Si and Mn C, All of the heats of formation of the oxides are exothermic so oxidation of the elements actually helps to raise the temperature of the bath. In addition the formation of CO helps to stir the bath and homogenise it whilst promoting further slag‐metal reactions The heats of formation can be slag metal reactions. calculated if the Wt% of the element in the molten bath is known. 2Al(l) + 2/3O2(g) = Al2O3  () / (g) ΔHR = ‐402  Kcal/mol / Si(l) + O2(g) = SiO2  ΔHR = ‐226  Kcal/mol Mn(l) + 1/2O2(g) = MnO ΔHR = ‐97.45  Kcal/mol (g) (g) 2C + O2(g) = 2CO (g)  ΔHR = ‐28  Kcal/mol 2Fe + O2(g) = 2FeO  ΔHR = ‐63.5 Kcal/mol Carbon alone is not enough to create a foaming slag. Often the chemistry of the slag itself is  ignored. The CO bubbles generated in the bath from direct oxidation of carbon, or those created in  the slag by mixing C and O or reducing FeO will all escape from the slag very quickly unless the slag  composition is correct. 17CHEMICAL ENERGY The system has below mentioned results: y ‐ Increase of production ‐ Reduction of production cost ‐ Reduction of electric energy Reduction of electric energy ‐ Reduction of tap to tap time ‐ Reduction of electrode consumption ‐ Better efficiency of the carbon ‐ Better homogenization of the melt g* According to temperature and flowing rate these values can be changed ‐ Low investment cost 18
  • 10. NEW CONCEPTS Scrap Pre‐Heating Systems One Charge EAF Some new technologies and concepts are developled by providers of steel making plants. EPC System Which one is the right investment for you? CVS has a new concepts and advises to reduce the energy consumption of EAF. 19S C R A P   P R E ‐ H E AT I N G   S Y S T E M 15 – 20 % of contained 15 20 % of contained energy as 100 150kwh/t in EAF during the oparation is gone out via duct as 100 ‐ 150kwh/t in EAF during oparation, is gone emissions. CVS scrap pre‐heater is a system which utilizes this heat energy to heat scrap in a bucket before charged into the EAF and thus contributes towards to energy saving. i Evacuated gas from the EAF is flowed to the combustion chamber, and via the second out way with another duct pipes, hot gas is flowed to the scrap buckets, gone into bucket to heat scraps and after that gone out from bottom of scrap bucket and via duct pipes, mentioned gases are gone to the FTP after gives existing heats to the scraps. g g p 20
  • 11. S C R A P   P R E ‐ H E AT I N G   S Y S T E M Preheating is burned by mixing with the gas from the EAF. This enables to eliminate an air pollution after dust collector. 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 b i t ti ill t be interrupted even th t d thoughh the preheating system run into a trouble. Recycling method of preheating system can be controlled separately from dust collector system. Proper adjustment of th preheating t P dj t t f the h ti temperature prevents th scrap b k t th scrap b k t t t the bucket the bucket from being deformed. 21S C R A P   P R E ‐ H E AT I N G   S Y S T E M Specifications Scrap Preheating system for improved efficiency of Meltshop Easy Solution Low Investment Cost Better Operation Main Profit:  Adaptable for Existing Automation Preheated scrap average temperature is  Maintenance Friendly between 150°C ‐ 200°C  The amount of energy saving is 20 – 30 kwh/ton  h f i i k h/ in practice. Preheating system: P h ti t ‐ Inlet temperature of preheater: approx. 800ºC – 200º C ‐ Outlet tempearture of preheater: approx 250º C – 50º C Outlet tempearture of preheater: approx. 250 C – 50 ‐ Temperature of preheated scrap: approx. 400º C – 100º C ‐ Temperature at combustion chamber inlet widely varies between 1200º C to 300º C according to  the time and conditions of the steelmaking stages. 22
  • 12. ONE CHARGE EAF 23ONE CHARGE EAFOur invention makes possible the continuous melting of ferrous materials such as sponge iron scrap iron,iron or iron ore in an electric arc furnace so that the electric arc is never turned off nor is the powerever reduced reduced. Our invention comprises an electric arc furnace for continuous charging of ferrous materials and semi continuous tapping of molten steel when it is adequately refined. 24
  • 13. ONE CHARGE EAFMost modern furnaces are designed to operate with a minimum of back‐charges. This is g p gadvantageous because charging is a dead‐time where the furnace does not have power on andtherefore is not melting. Minimizing these dead times helps to maximize the productivity of thefurnace. In addition, energy is lost every time when the furnace roof is opened.This can amount to 10–20 kWh/ton for each occurrence. Most operations aim for 2 to 3 buckets of scrap per heat and will attempt to blend their scrap to meet this requirement Our invention achieve a single requirement. bucket charge. 25ONE CHARGE EAFConstant flat bath allows for high electrical efficiency if a good foamy slag is maintained ! g y g y gOtherwise ‐ damage to refractory, accelerated delta wear, increased electrodeconsumption, decreased yield, increased power consumption, increased wear on oxygenlance.lanceSpecific Objectives of New Process‐ Lower specific capital costs‐ Lower primary energy consumption‐ High productivity/low conversion cost g p y‐ Flexibility in choice of feed materials‐ Lower T‐T‐T closer‐ Maintain maximum process flexibility Maintain maximum process flexibility‐ Increase product quality while maintaining cost competitiveness‐ More environmentally friendly and meet environmental requirements at minimum cost‐ Maximizing power input to the EAF by using a combination of energy sources Maximizing power input to the EAF by using a combination of energy sources‐ Optimized energy use and electrical power supply optimized to minimize losses 26
  • 14. ONE CHARGE EAFThis invention offers many features that are not available in the present art: ‐ the charge is continuous and several types of materials can be charged simultaneously;‐ the required melting time is reduced because the furnace works continuously; ‐ heat and emissions released into the environment are reduced because the furnace always works with closed cover; ‐ all motions required for charging, melting, refining and tapping the steel are automated;‐ the furnace tilting motion enables the steel to be refined during the melting process thus assuring a precise control of the steel temperature and composition;‐d d dust dispersion is reduced and, therefore, transformation yield is improved;  d d d h f f ld d‐ Modern operations aim for a tap‐to‐tap time of less than 45‐50 minutes. We aim for achieving tap‐to‐tap times of 40 t 45 minutes. t t ti f 40 to 45 i t 27ONE CHARGE EAF Low Powered EAF UHP  EAF CVS EAF Inputs p /ton kWh % Inputs /ton kWh % Inputs /ton kWh % Electrical 580 82 Electrical 420 65 Electrical 380 65 380 Chemical 125 18 Chemical 190 30 Chemical 190 30 Total 705 100 Burner 30 5 Burner 30 5 Outputs Total 640 100 Total 600 100 Steel 365 52 Slag 80 11 Outputs Outputs Electrical l i l 90 13 Steel 365 58 Steel 365 58 Misc 80 11 Slag 65 10 Slag 65 10 Offgas 50 7 Misc 15 2 Misc 10        2 0        2 C Water C Water 40 6 Offgas 130 20 Offgas 100 20 C Water 65 10 C Water 60     10 60     10 28
  • 15. E P C :   E N V I R O N M E N TA L   P R E H E AT I N G   &CONTINUOUS CHARGING SYSTEM 29EPC SYSTEM CVS MAKINA has a commercial cooperation with KR Tec company which has developed a New Generation concept in Arc Furnace Steelmaking, ENVIRONMENTAL PREHEATING & CONTINUOUS CHARGING SYSTEM (EPC). Idea behind the challenge is to recover the heat lost to FTP system by the application of Scrap Preheating. The EPC System combines the advantages of the preheating efficiency of the chamber and the continuous scrap feeding feeding. The EPC System is a new generation of economical arc furnace furnace. EPC system overcomes all the missing items of the existing Preheating system. 30
  • 16. EPC SYSTEM One of the issues of the EPC System is to charge the scrap independent of the electric arc furnace taken into consideration the environmental aspects. The EPC System is installed beside the EAF and the preheated scrap can be charged continuously by the telescopic feeder system in the melting chamber during Power On. Even during charging of the scrap basket into the EPC System, the system is always airtight and a small amount of dust can only escape. Furthermore, the design has been considerably simplified to increase the reliability and the profitability of the investment, reducing the ROI by less than 12 months. 31E P C   S Y S T E M :   A D VA N TA G E S ENERGY SAVING ENERGY SAVING The EPC reduces the electric energy consumption by approx. 80‐100 kWh/t compared to the  conventional EAF.  INDEPENDENT SCRAP CHARGING g g p p p y p Charging of the scrap basket is done with power‐on and independently from the furnace operation.  This improves the operation and reduce the Power off time  HIGHER PRODUCTIVITY Due to shorter power‐on and power‐off times. The productivity of the furnace can be increased by min. 20 % compared to the conventional EAF. HIGHER RETURN ON INVESTMENT The Th EPC S t System f t features llower conversion cost d t th preheating effect. F th i t due to the h ti ff t Furthermore hi h higher productivity because of less power‐on and power‐off are assured. 32
  • 17. E P C   S Y S T E M :   R E S P E C T   T O   N AT U R E MINIMUM DUST EMMISION During charging procedure the system/pre‐heating chamber is always in airtight situation which  reflects a minimum of pollution in the meltshop. LOW FTP CAPACITY REQUIREMENT Fume Treatment System capacity is reduced thank to the completely closed operation and flat bath  condition. LOW DOWNTIMES & MAINTENANCE No critical mechanical parts such as fingers, conveyors, water cooling which cause unforeseen  stoppages and maintenance. t d i t ADAPTABLE TO CONVENTIONAL METHOD Operation can be changed immediately to Conventional method by opening of the off gas ‐ bypass  Operation can be changed immediately to Conventional method by opening of the off gas bypass flap. LESS FLICKER LESS FLICKER Related to the flat bath operation, preheated scrap and the constant energy input, a reduced flicker  and less noise generation will be achieved. 33EPC SYSTEM: BENEFITS REGARDING ENVIRONMENT  Charging with airtight system  Mi i Minimum fume during scrap charging f d i h i  Cleaner working area g  Min. 30% less off gas  Min. 30 % less dust at the filter  Less noise  (melting of preheated scrap)  Respect of most environmental standards 34
  • 18. E P C   S Y S T E M :   F E AT U R E S Flat bath operation Controlled scrap quantity input through telescopic feeder system Charging during power on Preheating temperature controlled by PLC Minimized off gas volume related to airtight  system 35EPC SYSTEM The scrap basket will be charged into a drawer of the EPC system which is in waiting position. While this position the front wall of the drawer is closing the preheating chamber and the melting process in the EAF and preheating doesn`t have to be interrupted. After filling of the drawer by the scrap basket a slide gate on top of the EPC System will be closed. Than the drawer will be forwarded by hydraulic cylinders to the preheating chamber and the scrap falls smoothly inside the pre‐heating chamber where it will be preheated. If the drawer is in front position, the back wall of it, is closing to the pre‐heating chamber. A special design of the off gas duct together with a water cooled regulation flap allows to control the preheating effect in the pre‐heating chamber. 36
  • 19. EPC CHARGING HOPPER IN CHARGING POSITION PREHEATING POSITION 37EPC TELESCOPIC FEEDER IN STA RT P O S I T I O N FRONT POSITION 38
  • 20. EPC SYSTEM: MAIN COMPONENTS CLOSING SLIDE CHARGING B Y PA S S S Y S T E M G AT E OFF GAS FUNNEL OFF GAS R E G U L AT I O N FLAP CHARGING HOPPER TELESCOPIC SCRAP FEEDER SYSTEM EPC SYSTEM T R AV E L L I N G FRAME 39EPC SYSTEM 3D VIEWS 40
  • 21. EPC SYSTEM 3D VIEWS 41PROCESS STEPS OF EPC Refining phase of EAF ‐Preheating of 1st bucket of next heat in pre‐heating chamber ‐Charging of next bucket into charging hopper 42
  • 22. PROCESS STEPS OF EPC Charging of Preheating Chamber ‐Moving of charging hopper into pre‐heating chamber ‐Preheating of 2nd  bucket of next heat in pre‐heating chamber ‐Off gas flap of by pass system closed 43PROCESS STEPS OF EPC Preheating inside EPC ‐Start feeding of preheated scrap after tapping ‐Pre‐heating chamber half empty hopper can move backward to waiting  44 position
  • 23. PROCESS STEPS OF EPC Preheating inside EPC ‐Scrap bucket in waiting position S b k ti iti iti ‐Continuous feeding of scrap during power on ‐Control of preheating scrap temperature with by‐pass regulation flap 45PROCESS STEPS OF EPC Charging of Upper Hopper EPC ‐Start feeding of preheated scrap ‐Opening of sliding gate on top 46 ‐Charging of next bucket into charging hopper
  • 24. PROCESS STEPS OF EPC Parking Position of EPC ‐EPC system is moving backward on wheel mechanism underneath only for 47 maintenance purposeO P E R AT I O N A L   C Y C L E   D I A G R A MWITH EPC E A F C A PA C I T Y 100 TON T R A N S F O R M E R C A PA C I T Y 1 0 0 M VA 700 600 LIQUID STEEL 500 SCRAP WEIGHT 400 IN FIRST CHAMBER 300 SCRAP TEMP IN FIRST CHAMBER 200 SCRAP WEIGHT IN SECOND 100 CHAMBER - 0 5 10 15 20 25 30 37 42 47 52 48
  • 25. LIQUID STEEL LEVEL DURING CYCLEWITH EPC 140 E A F C A PA C I T Y 120 100 TON TRANSFORMER 100 C A PA C I T Y 1 0 0 M VA 80 LIQUID STEEL 60 SCRAP WEIGHT IN FIRST CHAMBER 40 SCRAP WEIGHT IN SECOND REPARATI EPARATION 20 CHAMBER APPING 1 HEAT CYCLE PR PRE TA - 0 5 10 15 20 25 30 37 42 47 52 49C O M PA R I S O N   O F   P R O D U C T I V I T Y PRODUCTION DIFFERENCE EPC - EAF CONVENTIONAL EAF Tra n s f o r m e r M VA 100 100 Ta p - w e i g h t t 100 100 Net working hours h/y 7.200 7.200 Power-on Time min 32 36 Power-off time min 6 11 Ta p - t o - Ta p - t i m e min 38 47 Production/hour t/h 157,89 127,66 Production/year t/y 1.136.842 919.149 Difference t/y 217.693 20 % PRODUCTIVITY INCREASE WITH EPC SYSTEM (100 TON – 100 MVA FURNACE) 50
  • 26. C O M PA R I S O N   O F   O P E R AT I O N A L   C O S T O P E R AT I O N A L C O S T D I F F E R E N C E CONVENTIONAL Unit price EPC- EAF EAF Unit EUR Consumption EUR/t Consumption EUR/t Electrical energy KWh/t 0,06 300,0 18,0 380,0 22,8 Oxygen Nm³/t 0,20 38,0 7,6 38,0 7,6 Electrodes kg/t 4,00 1,3 5,2 1,6 6,4 Fuel Nm³/t 0,20 3,0 0,6 6,0 1,2 Charged carbon kg/t 0,20 - - 7,0 1,4 Injected carbon kg/t 0,20 15,0 3,0 8,0 1,6 Scrap % 0,30 0,89 337,1 0,89 337,1 Dust removal kg/t 0,20 12,0 2,4 18,0 3,6 Lime kg/t 0,10 38,0 3,8 38,0 3,8 T O TA L 377,7 385,5 Savings EUR/t 7,8 8 €/T SAVING IN OPERATIONAL COST WITH EPC SYSTEM 51 (100 TON – 100 MVA FURNACE)C O M PA R I S O N   O F   C O N V E R S I O N   C O S T S EPC - EAF CONVENTIONAL EAF Annual Production t/y 1.136.842 919.149 Operational Cost EUR/t 378 385 Sales Price EUR/t 420 420 C A L C U L AT I O N Annual Operational Cost EUR/y -429.360.993 -354.312.293 Annual Fixed Cost EUR/y -30.000.000 -30.000.000 To t a l C o s t f o r Production EUR/y -459.360.993 -384.312.293 Sales Revenue EUR/y 477.473.684 386.042.553 Annual Profit EUR/y 1 8 . 11 2 . 6 9 1 1.730.261 Saving with EPC EUR/y 16.382.430 AROUND 16 MILLION EUR ANNUAL SAVING  WITH EPC SYSTEM WITH EPC SYSTEM (100 TON – 100 MVA FURNACE) 52
  • 27. C O M PA R I S O N   O F   R I O R O I C O M PA R I S O N 30 25 20 15 ROI FOR Million Euro 10 EPC-EAF EPC - EAF 5 CONV EAF - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 -5 ROI FOR CONV- EAF -10 -15 Time (month) 53EPC SYSTEM POWER FLUCTIONS VOLTAGE, CURRENT AND POWER FLUCTUATIONS; BEFORE AND AFTER SCRAP PREHEATING 54
  • 28. R E S U LT S Investment Costs of New Concepts Advantages Which Are More Than Competitors CVS provides tailor‐made different alternative solutions according to all your requests and requirements, as below; ‐ Layout ‐TTarget of I f Investment ‐ Process Conditions ‐ Budget 55 Yo u r   O n e ‐ S t o p Solution Provider for Meltshops & Rolling Mills 56
  • 29. R E F E R E N C E S   ‐ M E LT S H O P S Capacity Year of start‐ Year of start Customer Country Location Product Production units (tpy) up ABINSK ELECTROMET. PLANT Russia Abinsk 1.300.000 Billets Complete Meltshop 2012 ENERGOMASSPETSTAL Ukrain Kramatorsk 600.000 Ingot Complete Meltshop 2011 TAYBAH STEEL CO. Egypt Al Mansura 450.000 Billets Complete Meltshop 2011 ZELJEZARA NIKSIC AD. Montenegro Niksic 500.000 Billets EAF, FTP, WTP, AUX 2010 TOSCELIK A.S. Turkey Iskenderun 1.400.000 Billets&Slab Complete Meltshop 2009 KHAZAR BILLET CO. Iran Rasht 800.000 Billets EAF, LF, FTP, AUX 2008 CONSOLITED JORDANIAN STEEL CO. Jordan Amman 200.000 Billets Complete Meltshop 2007 UNITED IRON & STEEL MGF. CO. Jordan Amman 250.000 Billets EAF, LF, CCM, FTP 2007 NURSAN METALURJI A.S. NURSAN METALURJI A S Turkey Iskenderun 700.000 700 000 Billets Complete Meltshop Complete Meltshop 2006 CER CELIK A.S. Turkey Izmir 500.000 Billets EAF, LF, FTP, AUX 2006 57REFERENCES ‐ EAF Tap Capacity Shell dia. Transformer Year of  Customer Country Location (tons) (mm) (MVA) start‐up ABINSK ELECTROMET. PLANT Russia Abinsk 130 7.200 130 2012 ENERGOMASSPETSTAL Ukrain Kramatorsk 70 5.300 52 2011 TAYBAH STEEL CO. Egypt Al Mansura 60 5.300 52 2011 ZELJEZARA NIKSIC AD. ZELJEZARA NIKSIC AD Montenegro Niksic 65 5.300 5 300 52 2010 DHT METAL  Azerbaıjan Baku 30 3.900 25 2009 UNITED IRON & STEEL MFG CO. Jordan Amman 50 5.000 45 2009 TOSCELIK A.S. Turkey Iskenderun 155 7.300 130 2009 KHAZAR BILLET CO. KHAZAR BILLET CO Iran Rasht 100 6.100 6 100 78 2008 NURSAN METALURJI A.S. Turkey Iskenderun 130 7.200 135 2008 SOCIETE UNIVERS ACIER (SET 2) Morocco Casablanca 50 4.800 50 2008 SOCIETE UNIVERS ACIER (SET 1) Morocco Casablanca 50 4.800 50 2008 DETAL LTD. DETAL LTD. Azerbaijan Baku 85 6.000 80 2008 YESILYURT DEMIR CELIK A.S. Turkey Samsun 90 6.100 100 2008 COJSCO Jordan Amman 35 4.500 45 2007 IZMIR DEMIR CELIK A.S. Turkey Izmir 130 6.500 120 2007 BAKU POLAT DOKME LTD. BAKU POLAT DOKME LTD. Azerbaijan Baku 25 3.900 20 2007 AL HADDAD STEEL CO. Palestine Hibron 12 3.200 5 2007 CER CELIK A.S. Turkey Izmir 45 5.000 45 2007 NURSAN METALURJI A.S. Turkey Iskenderun 75 5.500 100 2006 YESILYURT DEMIR CELIK A.S. YESILYURT DEMIR CELIK A.S. Turkey Samsun 60 5.300 50 2006 EKINCILER A.S. Turkey Iskenderun 90 6.100 85 2005 KAPTAN DEMIR CELIK A.S. Turkey Istanbul 120 6.300 120 2005 JORDAN IRON & STEEL CO. Jordan Amman 13,5 3.100 7 58 2005
  • 30. R E F E R E N C E S   ‐ S E C O N D A R Y   M E TA L U R G Y Capacity Transformer Year of  Customer Country Location (tons) (MVA) start up start‐up ABINSK ELECTROMET. PLANT Russia Abinsk 130 24 2012 WONKANG METAL CO. S.Korea Seoul 16 VD/VOD 2011 CEMTAS Turkey Bursa 30 5 2011 ORUMIEH STEEL ORUMIEH STEEL Iran I Orumieh O i h 25 5 2011 ENERGOMASSPETSAL Ukrain Kramatorsk 140 24 2011 TAYBAH STEEL CO. Egypt Al Mansura 60 10 2011 KUMAS MANYEZIT (SET 2) Turkey Kutahya Producing Fused Mgo 2010 KARDEMIR A.S. Turkey Karabuk 120 22 2009 TOSCELIK A.S. Turkey Iskenderun 155 24 2009 KUMAS MANYEZIT (SET 1) Turkey Kutahya Producing Fused Mgo 2008 DETAL LTD DETAL LTD. Azerbaijan Baku 85 16 2008 KHAZAR BILLET CO. Iran Rasht 100 20 2008 YESILYURT DEMIR CELIK A.S. Turkey Samsun 90 16 2007 COJSCO Jordan Amman 35 8 2007 UNITED IRON & STEEL MGF CO. Jordan Amman 50 12 2007 COCSCO Jordan Zarqa 35 8 2007 JORDAN IRON & STEEL CO. Jordan Amman 15 5 2006 COJSCO Jordan Amman 45 8 2006 CER METAL A.S. Turkey Izmir 45 12 2006 NURSAN METALURJI A.S. Turkey Iskenderun 100 18 2005 KROMAN CELIK A.S. Turkey Kocaeli 100 18 199859REFERENCES ‐ CCM Sections Casting Nr. of  Nr of Year of  Year of Customer Country Location Product Radius Strands start‐up (mm) ABINSK ELECTROMET. PLANT Russia Abinsk 9 m 6 Square billets 130 ‐ 200 2011 ARCELOR MITTAL TEMIRTAU Kazakhstan Temirtau 9m 6 Square billets 100 ‐ 200 2011 TAYBAH STEEL CO. Egypt Al Mansura 6 m 4 Square billets 100 ‐ 160 2011 ZELJEZARA NIKSIC AD. Montenegro Niksic 5 m 4 Square billets 100 ‐ 140 2010 TOSCELIK A.S. Turkey Iskenderun 9 m 6 Square billets 130 ‐ 200 2009 KHAZAR BILLET CO. Iran Rasht 6 m 6 Square billets 100 ‐ 160 2008 Square & round  YESILYURT DEMIR CELIK A.S. Turkey Samsun 8 m 6 100 ‐ 200 2007 billets COJSCO Jordan d Amman 6 m 3 Square billets b ll 100 ‐ 160 2006 CER METAL A.S. Turkey Izmir 5 m 4 Square billets 140 2006 CER METAL A.S. CER METAL A S Turkey Izmir 5 m 5m 3 Square billets Square billets 200 2006 NURSAN METALURJI A.S. Turkey Iskenderun 5 m 6 Square billets 100 ‐ 150 2005 60
  • 31. REFERENCES ‐ FTP Plant Capacity Year of  Customer Country Location Technology (m3/h) start‐up ABINSK ELECTROMET. PLANT Russia Abinsk 2.300.000 Pulse‐jet FF 2012 JSC DNEPROSPETSSTAL Ukraine Zaporozhye 1.200.000 Pulse‐jet FF 2011 ENERGOMASSPETSTAL Ukraine Kramatorsk 1.200.000 1 200 000 Pulse‐jet FF Pulse jet FF 2011 TAYBAH STEEL CO. Egypt Al Mansura 600.000 Pulse‐jet FF 2011 ZELJEZARA NIKSIC AD. Montenegro Niksic 1.200.000 Pulse‐jet FF 2010 DHT METAL  Azerbaijan j Baku 650.000 Pulse‐jet FF j 2009 BILECIK DEMIR CELIK Turkey Bilecik 500.000 Pulse‐jet FF 2009 TOSCELIK A.S. Turkey Iskenderun 2.300.000 Pulse‐jet FF 2009 KARDEMIR A.S. Turkey Karabük 220.000 Pulse‐jet FF 2009 SOCIETE UNIVERS ACIER Morocco Casablanca 2.350.000 Pulse‐jet FF 2009 ALEZZ STEEL AL DEKHILIA (Set 2) Egypt Alexandria 1.400.000 Reverse‐air FF 2009 ALEZZ STEEL AL DEKHILIA (Set 1) Egypt Alexandria 1.400.000 Reverse‐air FF 2009 COJSCO Jordan Amman 600.000 Pulse‐jet FF 2006 YESILYURT DEMIR CELIK A.S. Turkey Samsun 2.000.000 Pulse‐jet FF 2006 CER CELIK ENDUSTRISI A.S. Turkey Izmir 1.200.000 Pulse‐jet FF 2006 NURSAN METALURJI A.S. Turkey Iskenderun 1.000.000 Pulse‐jet FF 2005 CER METAL A.S. Turkey Izmir 1.500.000 Pulse‐jet FF 20051 6REFERENCES ‐ MHS Customer Country Location Products ABINSK ELECTROMET. PLANT Russia Abinsk MHS for EAF,Scrap bucket, LF CMC SISAK Crotia Sisak MHS for EAF,Scrap bucket, LF KARDEMIR A.S. Turkey Karabuk MHS for LF TOSCELIK A.S. Turkey Iskenderun MHS for EAF,Scrap bucket, LF TAYBAH STEEL CO. Egypt Al Mansura MHS for EAF, LF COJSCO Jordan Amman MHS for EAF,Scrap bucket, LF KROMAN  Turkey Kocaeli MHS for LF 62
  • 32. REFERENCES ‐ OFF GAS SYSTEMS Customer C Country C Location i Products d ISDEMIR Turkey Iskenderun Skirt & Moveable Hood & Fixed Hood THYSSEN‐KRUPP AST Italy Terni WC hood for AOD ARCELOR MITTAL ANNABA Algeria g Annaba SMS 1 ‐ Moveable Hood & Fixed Hood ARCELOR MITTAL ANNABA Algeria Annaba SMS 2‐ Skirt & Movable Hood & Fixed Hood SALZGITTER FLACHSTAHL Germany Dusseldorf Off Gas Stack Cover 63R E F E R E N C E S   ‐ S PA R E   PA R T SCustomer Country Customer Country Customer CountryACCIAIERIE VALBRUNA Italy EKINCILER DEMIR CELIK Turkey MITTAL SKOPJE MITTAL SKOPJE MacedoniaAL RAJHI Saudi Arabia ELECTROSTAL Ukraine MOBARAKEH STEEL IranAL TUWAIRQI Saudi Arabia ELWOOD STEEL Belgium NATIONAL STEEL Saudi ArabiaALL EZZ GROUP Egypt ENGINEERING STEEL  Belgium NOVOROS METALL LTD. RussiaALSTOM POWER Italy BELGIUM NURSAN METALURJI AS NURSAN METALURJI AS TurkeyAMK ALCHEVSK Ukraine ERVIN AMASTEEL Belgium QATAR STEEL QatarARCELOR MITTAL RUHRORT Germany ETEAM Italy REVYAKINO RussiaARCELOR MITTAL TEMIRTAU Kazakhstan FERRIERE NORD ItalyARCELORMITTAL  SALZGITTER FLACHSTAHL Germany France FOLDER DenmarkDUNKERQUE SHARQ SOHAR Oman GERLAFINGEN SwitzerlandARCELORMITTAL HAMBURG Germany SIDENOR SA Greece GORKY STEEL RussiaARCELORMITTAL SKOPJE Macedonia SIDERURGICA BALBOA Spain G‐STEEL ThailandARCOSTEEL Egypt SIVAS DEMIR CELIK Turkey HALYVOURGIA THESSALIAS SA HALYVOURGIA THESSALIAS SA GreeceBAKU STEEL Azerbaijan SOHAR STEEL Oman HALYVOURGIKI GreeceBENTELER Germany SONASID Morocco INDUSTRIAS NACIONALES Dominican Rep. Bosnia SOVEL GreeceBH STEEL IZMIR DEMIR CELIK Turkey Herzegovina SUEZ STEEL gyp EgyptCARINOX Belgium JORDAN IRON & STEEL CO. JORDAN IRON & STEEL CO Jordan J d SWISS STEEL SuisseCEMTAS Turkey KAPTAN DEMIR CELIK Turkey THAME STEEL United KingdomCER METAL AS Turkey KARABUK DEMIR CELIK Turkey TIMKEN USACHARTER STEEL USA KOMOTEK Bulgaria TOSYALI HOLDING TOSYALI HOLDING TurkeyCMC SISAK Croatia KREMIKOVSKI Bulgaria UNITED IRON & STEEL MGF. CO. JordanCOJSCO Jordan KURUM STEEL Albania YESILYURT TurkeyCORUS Holland MAKEEVKA STEEL WORKS Ukraine 64 ZELJEZARA NIKSIC AD MontenegroDUFERCO Belgium MED STEEL  Syria

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