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CVS Makina. Company Presentation
Introduction




• CVS provides turn-key plants and
 equipment     solutions   for   STEEL
 SHOPS and ROLLING MILLS for
 long products.
Company highlights



• Location:   Gebze (Istanbul), Turkey

• Employees: 700 people (>200 engineers)

• Turnover:   € 75,000,000.00 (year 2008)

• Manufacturing area:   40.000           sqm
 covered
New developments in steel




 CVS has developed a new type of
 project, i.e.:

 ØThe      super-flexible   EAF   base
 Minimill concept
The Super-Flexible EAF base
     uper-
Minimill Concept



 • CVS has supplied the same category of
   E.A.F. to three steel-plants

 • All EAF’s were designed as rated 130 t
   capacity equipped with the latest
   technologies in terms of metallurgical,
   mechanical, electrical and automation
Main Design Concept



• Nr. of scrap bucket charge : 2

• Tapping weight            : 130 t

• TTT                       : 40 min.

• Tapping temp.             : 1600-1620°C

• Hot heel amount           : 20-40 t
Tap-
Tap-to-Tap Time Cycle



• Charging                      : 3 min.
• Tapping                       : 3 min.
• Preparation                   : 4 min.
 (EBT filling, gunning, etc.)
 Power - off Time               : 10 min.
 Power - on Time                : 30 min.
 TTT                            : 40 min.
Plant layout concepts



The plant layout is studied to obtain the
below results :
•Adequate size of area occupied

•Adequate number of personel required

•Optimum productivity and limited cost

•Future extension possibility
E.A.F. main features



• The main core of the steelmaking is EAF, the
  complexity is coming from various types and
  blends of scraps and scrap substitutes such as
  DRI and HBI.
• Additional chemical energy based on carbon,
  fuel and oxygen is used as substitute of electric
  power.
• Due to the dynamic process input energy should
  be controlled carefully.
• Slag stability

• Control the slag foaming by controlling
  slag composition

• High impedance application

• SIM-ARC electrode regulation design
Slag Foaming
Other Features of E.A.F.:
                  E.A.F.:


• Hot heel practice

• Control of liquid steel

• Chemical energy input

• Fast scrap charging

• New roof lifting mechanism design

• Scrap yard flexibility
New EAF Roof Lifting Mechanism
CVS- E.A.F.
CVS- E.A.F. Projects
CVS-
CVS-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.
CVS-
CVS- Burner Positioning Inside Furnace




   ► The lance manipulator for the Electric Arc Furnace is primarily designed for
      safe oxygen injection. Same manipulator is used for carbon injection as
      well.

   ► 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.
LADLE FURNACE (LF)


• Optimum size
• Essential part of the
  secondary metallurgy
  treatment
LF Advantages


• 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
LF Design Advantages


• Water-cooled ladle roof
  equipped with indirect fume
  collecting hood to reduce
  steel oxidation
• Electro-hydraulic electrode
  regulation
• Electrode arms with reduced
  electrode pitch diameter
• Roof lifting mechanism via
  hydraulic cylinder
PERFORMANCES                       Plant A                    Plant B                  Plant C
      Plant Unit:                                              E.A.F.
  Tapping weight (t)      start-up 130/present 140   start-up100/present 135t   start-up 130/present150
      TTT (min.)          50-56           40-48      38-42              48-55   42-47           55-60
   Productivity (t/h)     170             185        150                167             150-185
Electric consp.( kWh/t)   380-410         340-380    380-410        370-400             360-390
Electrode consp. (kg/t)   1.5-1.6        1.20-1.30   1.5-1.6        1.35-1.50           1.25-1.35
  O2 consp. (Nm³ /t)      43                  42     38                  40              30-35
 Carbon consp.(kg/t)      15             15-20       20                  22              18-22
   Refractory (kg/t)      4.20                3.60   3.67               3.35
 Shell life (# of heat)   480                 500    450                750
 Roof delta life (heat)   520                 560    450                700
  Lime comp. (kg/t)       45-50           30-35      45                  42              45-50
   PRODUCTION
     RECORD:
       heat/day           32                   33    37                  29                25
         t/day            4100                4440   3597               4013              3750
PERFORMANCES           Plant A       Plant B       Plant C

      Plant unit:                        L.F.
Electric consumption     26 - 33       30 - 33       30 – 35
        (kwh/t)
Electrode consumption   0.26 - 0.31   0.31 - 0.32   0.35 - 0.40
        (kg/t)
  Lime consumption       11 – 14         6-8          8 - 10
        (kg/t)
   Ladle refractory      2.5 - 2.6     2.1 - 2.3
  consumption (kg/t)
   Ladle life (heat)     90 - 92       80 - 95
Company                   Plant A                Plant B                Plant C

      Plant unit:                                      E.A.F.
    Furnace Type          AC-EBT/Turret gantry   AC-EBT/Turret gantry   AC-EBT/Buggy gantry

  Upper shell (Ømm)              7,200                  7,200                  7,200
  Lower shell (Ømm)              7,400                  7,400                  7,400

Upper shell height (mm)          3,000                  3,000                  3,000

 Serios reactor(MVAr)        ON-LOAD 36             ON-LOAD 46               ON-LOAD

  Transformer (MVA)            120+10%                   135                 130+20%

   Max. Sec.Volt (V)             1,200                  1305

   Inner volume (m³)             ≥155                   ≥155                   ≥155

 Scrap bucket vol (m³)            146                    130                   140

   Electrode (Ømm)             24” (610)              26” (660)              24” (610)

Max. Sec. Current (kA)            70                     70                     75

     PCD (Ømm)                   1300                   1300                   1300

     Electrod arm             Cu-cladded             Cu-cladded             Cu-cladded

Oxy/fuel burner+sup.Jet        5+1 EBT                5+1 EBT                4+1 EBT

 SVC capacity (MVAr)              170                    175                   200
Company               Plant A      Plant B       Plant C
    Plant unit:                          L.F.
 Transformer (MVA)        20+20%       18+20%        20+20%

  Max. Secondary            386          330           382
    Voltage (V)
  Max. Secondary            37            40            40
   Current (kA)
 Electrode (Ø, mm)          406          406           450
   PCD (Ø, mm)              750          700           750
 Electrode arm type     Cu-cladded     Bus-tube     Cu-cladded
Heating rate (°C/min)   Max. 5°C/min   4.5°C/min   max. 5 °C/min
Company               Plant A              Plant B              Plant C
   Plant unit:                     Fume Treatment Plant - FTP
 Dedusting Plant:        (Existing)        (Existing, CVS          (New CVS
                                              Supply)               Supply)
  Emission type           EAF primary & secondary + LF/MHS emissions
    Filter Type       Pulse-jet off-line   Pulse-jet off-line   Pulse-jet off-line
Filter surface (m²)       22.000               30.385               22.300
 Main fans (m³/h)      6 x 400.000          6 x 500.000          4 x 600.000
Elect. Motors (KW)                             6 x 800             6 x 1.400
 Sucking capacity
                        2.400.000            3.000.000            2.400.000
      (m³/h)
Outlet dust content
                            ≤ 20                 ≤ 20                 ≤ 20
     (mg/Nm³)
Company                  Plant A              Plant B             Plant C
       CCM                   Existing             Existing       NEW (CVS supply)
  Machine Type           Curved mould          Curved mould      Curved mould 1 m.
    Radius (m)                  6                     5                9/17
Number of strands               7                     6                  6
Cast section (mm)       Square 100 - 150      Square 100 - 140   Square 130 – 200
Tundish capacity (t)         30 max.              28 max.             35 max.
Mould level control         magnetic               camera             Co-60
      M-EMS                    yes                   no                 Yes
  Oscillating unit         mechanical            mechanical          Hydraulic
    Dummy bar                  rigid               flexible            Rigid
       W/S                 2 drives/std          2 drives/std       3 drives/std
   Billet cutting         oxy-gas torch        Hydraulic shear     oxy-gas torch
Discharge system         Liftable transfer     Cross transfer      Cross transfer
   Billet transfer      W.B. Cooling bed      W.B. Cooling bed   W.B. Cooling bed
  Casting speed        sp.140 mm 3.2 max     sp.150 mm 2.8 max   sp.150 mm 3.1 av.
                                                                 sp.130 mm 4.1 av.
Conclusions
Conclusions


• In the last few years, CVS has supplied nr. 3 same size
  EAF’s.
• One of those projects was also a complete “turn-key”
  green-field project and it has been completed in 16
  months.
• The three EAF’s are using in the range of 90t to 150t
  liquid steel without modifications. Since many
  restrictions at their beginning stage of start-up. 160t is
  expected in the near future either with high bulk
  density scrap or with 3 charges.
• These superflexible approach to steel making practise
  is giving significant advantages to investers in terms
  of their present and future’s plans.
Thank You For Your Patience
      www.cvs.com.tr

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STEELMAKING TECHNOLOGIES AND NEW INNOVATIONS IN MELTSHOPS - CVS MAKINA

  • 1.
  • 2. CVS Makina. Company Presentation
  • 3. Introduction • CVS provides turn-key plants and equipment solutions for STEEL SHOPS and ROLLING MILLS for long products.
  • 4. Company highlights • Location: Gebze (Istanbul), Turkey • Employees: 700 people (>200 engineers) • Turnover: € 75,000,000.00 (year 2008) • Manufacturing area: 40.000 sqm covered
  • 5. New developments in steel CVS has developed a new type of project, i.e.: ØThe super-flexible EAF base Minimill concept
  • 6. The Super-Flexible EAF base uper- Minimill Concept • CVS has supplied the same category of E.A.F. to three steel-plants • All EAF’s were designed as rated 130 t capacity equipped with the latest technologies in terms of metallurgical, mechanical, electrical and automation
  • 7. Main Design Concept • Nr. of scrap bucket charge : 2 • Tapping weight : 130 t • TTT : 40 min. • Tapping temp. : 1600-1620°C • Hot heel amount : 20-40 t
  • 8. Tap- Tap-to-Tap Time Cycle • Charging : 3 min. • Tapping : 3 min. • Preparation : 4 min. (EBT filling, gunning, etc.) Power - off Time : 10 min. Power - on Time : 30 min. TTT : 40 min.
  • 9. Plant layout concepts The plant layout is studied to obtain the below results : •Adequate size of area occupied •Adequate number of personel required •Optimum productivity and limited cost •Future extension possibility
  • 10.
  • 11. E.A.F. main features • The main core of the steelmaking is EAF, the complexity is coming from various types and blends of scraps and scrap substitutes such as DRI and HBI. • Additional chemical energy based on carbon, fuel and oxygen is used as substitute of electric power. • Due to the dynamic process input energy should be controlled carefully.
  • 12.
  • 13. • Slag stability • Control the slag foaming by controlling slag composition • High impedance application • SIM-ARC electrode regulation design
  • 15. Other Features of E.A.F.: E.A.F.: • Hot heel practice • Control of liquid steel • Chemical energy input • Fast scrap charging • New roof lifting mechanism design • Scrap yard flexibility
  • 16. New EAF Roof Lifting Mechanism
  • 18. CVS- CVS-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.
  • 19. CVS- CVS- Burner Positioning Inside Furnace ► The lance manipulator for the Electric Arc Furnace is primarily designed for safe oxygen injection. Same manipulator is used for carbon injection as well. ► 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.
  • 20.
  • 21. LADLE FURNACE (LF) • Optimum size • Essential part of the secondary metallurgy treatment
  • 22. LF Advantages • 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
  • 23. LF Design Advantages • Water-cooled ladle roof equipped with indirect fume collecting hood to reduce steel oxidation • Electro-hydraulic electrode regulation • Electrode arms with reduced electrode pitch diameter • Roof lifting mechanism via hydraulic cylinder
  • 24. PERFORMANCES Plant A Plant B Plant C Plant Unit: E.A.F. Tapping weight (t) start-up 130/present 140 start-up100/present 135t start-up 130/present150 TTT (min.) 50-56 40-48 38-42 48-55 42-47 55-60 Productivity (t/h) 170 185 150 167 150-185 Electric consp.( kWh/t) 380-410 340-380 380-410 370-400 360-390 Electrode consp. (kg/t) 1.5-1.6 1.20-1.30 1.5-1.6 1.35-1.50 1.25-1.35 O2 consp. (Nm³ /t) 43 42 38 40 30-35 Carbon consp.(kg/t) 15 15-20 20 22 18-22 Refractory (kg/t) 4.20 3.60 3.67 3.35 Shell life (# of heat) 480 500 450 750 Roof delta life (heat) 520 560 450 700 Lime comp. (kg/t) 45-50 30-35 45 42 45-50 PRODUCTION RECORD: heat/day 32 33 37 29 25 t/day 4100 4440 3597 4013 3750
  • 25. PERFORMANCES Plant A Plant B Plant C Plant unit: L.F. Electric consumption 26 - 33 30 - 33 30 – 35 (kwh/t) Electrode consumption 0.26 - 0.31 0.31 - 0.32 0.35 - 0.40 (kg/t) Lime consumption 11 – 14 6-8 8 - 10 (kg/t) Ladle refractory 2.5 - 2.6 2.1 - 2.3 consumption (kg/t) Ladle life (heat) 90 - 92 80 - 95
  • 26. Company Plant A Plant B Plant C Plant unit: E.A.F. Furnace Type AC-EBT/Turret gantry AC-EBT/Turret gantry AC-EBT/Buggy gantry Upper shell (Ømm) 7,200 7,200 7,200 Lower shell (Ømm) 7,400 7,400 7,400 Upper shell height (mm) 3,000 3,000 3,000 Serios reactor(MVAr) ON-LOAD 36 ON-LOAD 46 ON-LOAD Transformer (MVA) 120+10% 135 130+20% Max. Sec.Volt (V) 1,200 1305 Inner volume (m³) ≥155 ≥155 ≥155 Scrap bucket vol (m³) 146 130 140 Electrode (Ømm) 24” (610) 26” (660) 24” (610) Max. Sec. Current (kA) 70 70 75 PCD (Ømm) 1300 1300 1300 Electrod arm Cu-cladded Cu-cladded Cu-cladded Oxy/fuel burner+sup.Jet 5+1 EBT 5+1 EBT 4+1 EBT SVC capacity (MVAr) 170 175 200
  • 27. Company Plant A Plant B Plant C Plant unit: L.F. Transformer (MVA) 20+20% 18+20% 20+20% Max. Secondary 386 330 382 Voltage (V) Max. Secondary 37 40 40 Current (kA) Electrode (Ø, mm) 406 406 450 PCD (Ø, mm) 750 700 750 Electrode arm type Cu-cladded Bus-tube Cu-cladded Heating rate (°C/min) Max. 5°C/min 4.5°C/min max. 5 °C/min
  • 28. Company Plant A Plant B Plant C Plant unit: Fume Treatment Plant - FTP Dedusting Plant: (Existing) (Existing, CVS (New CVS Supply) Supply) Emission type EAF primary & secondary + LF/MHS emissions Filter Type Pulse-jet off-line Pulse-jet off-line Pulse-jet off-line Filter surface (m²) 22.000 30.385 22.300 Main fans (m³/h) 6 x 400.000 6 x 500.000 4 x 600.000 Elect. Motors (KW) 6 x 800 6 x 1.400 Sucking capacity 2.400.000 3.000.000 2.400.000 (m³/h) Outlet dust content ≤ 20 ≤ 20 ≤ 20 (mg/Nm³)
  • 29. Company Plant A Plant B Plant C CCM Existing Existing NEW (CVS supply) Machine Type Curved mould Curved mould Curved mould 1 m. Radius (m) 6 5 9/17 Number of strands 7 6 6 Cast section (mm) Square 100 - 150 Square 100 - 140 Square 130 – 200 Tundish capacity (t) 30 max. 28 max. 35 max. Mould level control magnetic camera Co-60 M-EMS yes no Yes Oscillating unit mechanical mechanical Hydraulic Dummy bar rigid flexible Rigid W/S 2 drives/std 2 drives/std 3 drives/std Billet cutting oxy-gas torch Hydraulic shear oxy-gas torch Discharge system Liftable transfer Cross transfer Cross transfer Billet transfer W.B. Cooling bed W.B. Cooling bed W.B. Cooling bed Casting speed sp.140 mm 3.2 max sp.150 mm 2.8 max sp.150 mm 3.1 av. sp.130 mm 4.1 av.
  • 30. Conclusions Conclusions • In the last few years, CVS has supplied nr. 3 same size EAF’s. • One of those projects was also a complete “turn-key” green-field project and it has been completed in 16 months. • The three EAF’s are using in the range of 90t to 150t liquid steel without modifications. Since many restrictions at their beginning stage of start-up. 160t is expected in the near future either with high bulk density scrap or with 3 charges. • These superflexible approach to steel making practise is giving significant advantages to investers in terms of their present and future’s plans.
  • 31. Thank You For Your Patience www.cvs.com.tr