STEELMAKING TECHNOLOGIES AND NEW INNOVATIONS IN MELTSHOPS - CVS MAKINA

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STEELMAKING TECHNOLOGIES AND NEW INNOVATIONS IN MELTSHOPS BY CVS MAKINA

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STEELMAKING TECHNOLOGIES AND NEW INNOVATIONS IN MELTSHOPS - CVS MAKINA

  1. 1. CVS Makina. Company Presentation
  2. 2. Introduction • CVS provides turn-key plants and equipment solutions for STEEL SHOPS and ROLLING MILLS for long products.
  3. 3. Company highlights • Location: Gebze (Istanbul), Turkey • Employees: 700 people (>200 engineers) • Turnover: € 75,000,000.00 (year 2008) • Manufacturing area: 40.000 sqm covered
  4. 4. New developments in steel CVS has developed a new type of project, i.e.: ØThe super-flexible EAF base Minimill concept
  5. 5. 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
  6. 6. 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
  7. 7. 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.
  8. 8. 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
  9. 9. 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.
  10. 10. • Slag stability • Control the slag foaming by controlling slag composition • High impedance application • SIM-ARC electrode regulation design
  11. 11. Slag Foaming
  12. 12. 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
  13. 13. New EAF Roof Lifting Mechanism
  14. 14. CVS- E.A.F. CVS- E.A.F. Projects
  15. 15. 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.
  16. 16. 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.
  17. 17. LADLE FURNACE (LF) • Optimum size • Essential part of the secondary metallurgy treatment
  18. 18. 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
  19. 19. 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
  20. 20. 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
  21. 21. 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
  22. 22. 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
  23. 23. 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
  24. 24. 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)
  25. 25. 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.
  26. 26. 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.
  27. 27. Thank You For Your Patience www.cvs.com.tr

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