General Description of Fume Treatment Project for DSS company in Ukraine by CVS MAKINA , which is designer, manufacturer, erector companies for all the units for meltshop and rolling mills explaining themselves as the dedicator to steel sector.
1. DNEPROSPETSSTAL
FUME TREATMENT PROJECT DESCRIPTION
CVS MAKINA - Company Presentation
-Design
-Manufacturing Offices:
- Erection - CVS Headquarter
- Training (Turkey)
- Consultancy - CVS Europe (Italy)
-Innovation - CVS Egypt
- Process - CVS Ukraine
Development - CVS Iran
info@cvs.com.tr www.cvs.com.tr
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. CVS
Why FTP Is Important?
Why FTP Is Important?
CVS
Why FTP Is Important?
Why modern dedusting systems are crucial
Dust Emission - 10 to 25 kg/ton steel.
The most important goals are
high reliability,
strict compliance with prescribed
threshold values
reasonable energy consumption.
CVS Advantages
Cost-efficient production
Maximized productivity
Low consumption levels
Short delivery times
Consistently high availability
Flexibility of charge material
Preparation for future environmental
requirements
4. CVS
What FTP means for EAF?
In the field of environmental protection
inside the electric steel meltshop, a very
important application is the collection
and treatment of the primary fumes
produced by the EAF process and
escaping from the IV hole on furnace
roof. The emission flowrate,
temperature, heat load and composition
are continuously and suddenly changing
during the power-on phases. The main
pollutant generated by the EAF process
are the fine dust of iron oxide and other
heavy metals, volatile compounds, but
also the quantity of CO and VOC are
high.
CVS
What to consider during decision?
-To achieve high reliability and favorable
operating costs requires the right design.
-The more cleanly the process parameters are
adapted to one another and the more precisely
the design is tailored to the up-stream
aggregate, the more smoothly the operation
will run.
-Long-lasting, low-maintenance components
virtually eliminate unplanned downtimes.
A dedusting system requires sensible
investments. That is why it is so important for
the system to be able to accommodate future
expansions of production and potentially
stricter environmental regulations - without
requiring significant modification and
conversion costs. And for the same reason,
you need a plant layout that also offers
flexibility for the future.
5. CVS - FTP
Why to Choose CVS
CVS
Why to choose CVS?
CVS offers the entire spectrum of dedusting technology from a single source, always in
close collaboration with our customer's steel production plant specialists. This is our
approach for creating perfectly coordinated, economically viable solutions
Good reasons for our dedusting
solutions
•Guaranteed compliance with
agreed-upon limit values
•Tailored dedusting units using
comprehensive mini-mill expertise
•Future emission requirements are
already taken into account in the
plant layout
•Problem-free operation with low
service requirements
•Turnkey solutions from a single
source - with one contact, and one
person in charge
6. CVS - FTP
Dedusting solutions for your EAF steel mill?
Clean Environment
High availability, high reliability and
guaranteed elimination of residues such as
dioxin from an electric arc furnace. In other
words, you produce steel while we make
sure your systems and your environment
stay clean.
Maintenance? Short, planned and efficient
Robust components, high-quality
workmanship and the right design keep
maintenance to a minimum. Our systems
also allow bags to be changed during
operation - another way we contribute to
high availability.
Equipped for future demands today
CVS designs your system to harmoniously
accommodate any future expansions with
no long downtimes or start-up problems.
Thus, with your initial investment, we've put
you on the right track to effectively limiting
subsequent costs later on
CVS - FTP
AUTOMATION
Smooth operation - fully
automated
CVS automation ensures
flexible, secure operation, a
high degree of safety for
people and machinery and
high efficiency over the entire
life-cycle of the system.
Advanced solutions, such as
an inverter for large drives,
contribute to decreased energy
costs by allowing output and
energy consumption to be
continuously adapted to
production demands.
7. CVS - FTP
AUTOMATION
Operation of complete dedusting system
is syncronised by automation system.
Distribution of flow to primary and
secondary section of EAF is controlled by
two dampers located on the lines
actuated automatically by automation.
Damper position and main fan speeds
according to 5 main modes of furnace
operation can be changed by HMI in FTP
control room.
Additionally, fan speed is adjusted during
melting phase according to the value coming
from pressure transmitter measuring the
pressure inside combustion chamber.
CVS
Converter Off-Gas System
WE FOLLOW LAST TECHNOLOGIES
WHEN WE MANUFACTURE OFF GAS
SYSTEMS
9. DSS
COMPANY PROFILE
A leader in production of special steel products, Dneprospetsstal (DSS) is based in
Zaporozhye, Ukraine, and employs about 6 200 people.
Originally founded as a state-run enterprise in 1932, today Dneprospetsstal’s activities cover
the design, manufacture and distribution of stainless, tool, high-speed (including powder
made steel), bearing and alloy structural steel products.
DSS’ products are used in the manufacture of machinery parts, tools for metal and alloy
machining, seamless pipes and bearings.
DSS enjoys a unique position as a high added-value producer. The company’s location in
Ukraine gives it a favorable geographical advantage, placing it in proximity to two of its
largest consumer regions: the CIS and the EU. With partners and distributors in more than
15 different countries, DSS casts a wide net over world markets; its products are used and
sold in over 60 countries.
Dneprospetsstal aims at retaining leadership in the domestic market and expansion of its
presence in the markets of Russia, Europe, America and Asia using existing and new
distribution channels.
The Company also strives for entering into strategic alliances and finding partners for
cooperation in the field of subsequent metal processing.
DSS
PRODUCTION CHART
Dneprospetsstal
produces more
than 800 grades
and 1000 cross-
sections.
DSS manufacturing
process is an
optimal
combination of
different
technological
procedures, which
provide making of
high quality
products with
desired properties,
10. DSS
ECOLOGICAL VISION
Goal
To create an
environmentally
safe business.
Result
Investing significant
funds annually into Idea
environmental Environmental
projects like protection means
purification equipment concern about
and the introduction of people's health
energy saving
technologies.
DSS
FTP DECISION
Dneprospetsstal constantly develops and modernizes production facilities, new technologies
developed and up-to-date equipment implemented result in the highest quality product
performance.
The following design criteria have been considered during the decision of the system:
•minimum operation and maintenance costs;
•optimal utilization of spaces inside / outside the meltshop;
•automatic operation, “hands-off” type; and
•twenty-four hours operation.
11. DSS FTP PROJECT
PLANT PHOTO
DSS FTP PROJECT
GENERAL IDEA
The purpose of the new FTP is the control and treatment of the following emission sources:
Primary emissions from the new 60 t E.A.F.;
Secondary emissions from the new 60 t E.A.F.;
Emissions from the new twp pcs. 60 t L.F.;
Emissions from the new Material Handling System (MHS).;
The main topics of the new FTP are listed below:
•Suction of the EAF primary emissions from the IV hole elbow installed over the EAF roof;
•Suction of the EAF secondary emissions from a canopy hood installed on the roof building;
•Suction of the 2 pcs LF emissions from the side draft hood installed above the LF roof;
•Suction of the MHS emissions from a set of dedicated local hoods;
•Cooling of EAF primary emissions by means of a natural cooler (hairpin design);
•Filtering of the dirty gases by means of a bag filter, pulse-jet bag cleaning & negative
pressure type;
•Exhausting of the cleaned gases by means of two main ID fans driven by AC motors with
inverter;
•Emission into the atmosphere of the cleaned gases by means of dedicated stack sized.
12. DSS FTP PROJECT
DESIGN
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.
DSS FTP PROJECT
PROCESS FLOWSHEET
14. DSS FTP PROJECT
DESIGN VALUES
EAF secondary emissions (canopy hood):
3 o
•Suction capacity (tapping/charging): 800.000 Nm /h @ 80 C
3 o
•Ventilation capacity (melting): 370.000 Nm /h @ C
3
•Actual fume flowrate (tapping/charging): 1.030.000 m /h
3
•Actual fume flowrate (melting): 440.000 m /h
•Hot fumes spreading velocity approx. (charging): 2.20 m/sec
EAF primary emission (melting phase):
3 o
•Fume suction capacity: 45.000 Nm /h @1.600 C
o
•Fume temperature at cooler outlet: 300 C
Ladle Furnace
o
•Suction capacity: 37.000 Nm3/h @ 150 C
3
•Actual fume flowrate: 60.000 m /h
•2 LF total suction capacity: 74.000 Nm3/h
o
•Temperature at suction duct inlet:90 C
3
•2 LF Actual fume flowrate: 110.000 m /h
Material handling system emission
o
•Suction capacity: 50.000 Nm3/h @ 50 C
3
•Actual fume flowrate: 60.000 m /h
DSS FTP PROJECT
BAG FILTER DESIGN
Total design capacity: m3/h 1.200.000
Max. working temperature: °C 120
Compartments: nr. 16
Bag cleaning system: pulse jet off-line
Compartment off-line: nr. 2
Total filtering surface: m² 14.855
Net filtering surface: m² 12.998
Clean gas dust content: mg/Nm³ 20
Filter headers: nr. 16
Blowing electro valves: nr. 264 – 2 inc
Filtering bags: nr. 4.224 pcs
Filtering bag material: polyester needle felt
Filtering tissue weight: g/m² 500
Filtering bag dimensions: mm 160 x 7.000
15. DSS FTP PROJECT
EAF PRIMARY EMISSIONS
The EAF primary emissions are controlled by a set of water cooled ducts (WCD) and radiant or
single-walled ducts (SWD); while the final hot gas cooling is performed by the natural cooler.
The system dedicated to the EAF Primary Emission consists of the following components:
An elbow with duct, installed over the combustion chamber roof and provided with a
pneumatically adjustable sliding sleeve. The purpose of the sliding sleeve is to regulate the gap
between the IV hole elbow (part of the EAF roof) and the consequent WCD line. Through this
gap the necessary external air is sucked to dilute the primary gas and to permit the CO
combustion in the chamber.
A combustion chamber made of water-cooled panels and concrete / refractory in the bottom
part; it is sized to guarantee suitable retention time for CO full combustion and to allow for
velocity reduction to enable heavy particles to settle.
A set of water-cooled ducts (WCD) are designed to cool down the hot gases coming from the
combustion chamber and to convey them up to the radiant ducts.
A Natural Cooler designed to cool down the gases up to a temperature to allow the mixing
with the EAF Secondary Emission line. The Natural Cooler consists of a bundle of radiant ducts
of suitable diameter to avoid clogging.
A set of radiant ducts (SWD) of single walled type are foreseen to convey the gases from the
WCD to the Natural Cooler.
A regulation damper of multi-flaps type driven by electric actuator designed to adjust the
suction flow in the line.
DSS FTP PROJECT
EAF SECONDARY EMISSIONS
The EAF Secondary Emissions are controlled
through the following components:
A large canopy hood installed on the top of the
building roof and designed to collect the EAF
emission during charging / tapping phases and to
suck the necessary dilution air to finally cool down
EAF primary gases to reach a temperature
acceptable by the filtering unit. The canopy hood
volume and shape are designed to allow an
adequate “resident time” of the emission during the
EAF most critical operating conditions.
Two collectors of “trombone” type are installed
inside the canopy hood to improve the internal
suction efficiency.
A main duct line is foreseen to convey the secondary emissions from the two collectors to the
filtering unit. The diameter of the duct is sized in order to obtain an optimal internal gas speed
(approx. 29-30 m/sec) to avoid dust settlement.
An axial cyclone is installed upstream the filter unit in order to stop sparks and heavy particles in
any operating conditions.
A safety damper, pneumatically actuated for a quick response when gas temperature exceed the
maximum continuous working temperature of the filtering unit (about 130°C).
16. DSS FTP PROJECT
LF & MHS EMISSIONS
The control of the LF emissions is The following equipment carries out the
performed through the following control of the emission generated by the
components: Material Handling System:
A side-draft hood set-up on LF roof top •A set of local suction hoods (to be defined
and designed to collect the primary and sized by the Material Handling
gases generated by the LF (this hood System supplier) to be located as close as
is part of the LF its self). possible to the emission sources.
A set of radiant ducts of single walled •A set of radiant ducts to connect the local
type designed to convey the gases hoods with a common duct and then
from the side draft hood to the mixing connected with the EAF secondary
point with the EAF secondary emission emission main ducts.
main ducts. 3. A booster fan of centrifugal type is
A booster fan of centrifugal type is provided to compensate the losses in the
provided to compensate the losses in duct, thus allowing an efficient suction.
the duct, thus allowing an efficient The fan is driven by a LV motor and is
suction. The fan is driven by a LV fitted with a regulation damper actuated by
motor and is fitted with a regulation electric actuator.
damper actuated by electric actuator.
DSS FTP PROJECT
FILTERING UNIT
The emissions filtration is carried out through one negative pressure bag filter with off-line pulse-jet
bag cleaning design. This type of filter works in under-pressure with the main fans located afterward
and is equipped with an automatic bag cleaning system based on the use of compressed air jet into
the bags.
The high efficiency of the bag cleaning system requires a reduced volume of injected air at low
pressure, thus reducing air consumption and pressure drop.
The main advantages of suggesting filters
are summarized as follows:
- reduced overall filter dimensions, thanks to
a filtering surface far lower than that of a
filter cleaned by a reverse air operation;
- fans located downstream the filter,
consequently high efficiency impellers can
be used thanks to the small dust content in
the treated gas; no out of balance risk is
faced;
- reduce pressure drop thus low energy and
compressed air consumption;
- easy maintenance and bags replacing.
17. DSS FTP PROJECT
BAG FILTER
Huge flowrate calls for pulse jet filter which are
suction-type filters, equipped with compressed air
automatic bag cleaning system. The filter itself is
composed of 2 parallel lines, made up of several
compartments containing a fixed number of bags.
Each compartment consists of a “raw gas”
chamber below and a “clean gas” chamber
above divided by the bag supporting plate. The
lower chamber composes the filter body, contains
the filtering bags and the dust collecting hoppers.
The upper chamber contains the injectors for the
compressed air distribution to the bags for
cleaning purpose.
The two chambers are connected to the central collector respectively to the gas inlet and outlet by
means of separation dampers. Dampers for lower chambers are manually actuated, being utilized
in closed position as an additional safety in the event of maintenance or inspection; the dampers of
the upper chambers, instead, are provided with pneumatic actuators, being automatically closed
while performing maintenance and bag cleaning in OFF-LINE mode.
The cleaning system of the filtering bags is located inside the “clean gas” chamber. It is composed
of one distributor per row of bags, completed with compressed air feeder to each bag.
DSS FTP PROJECT
EXHAUSTING SYSTEM
The suction and exhaust of the various emissions is performed
by the following equipment:
Three centrifugal fans located downstream the filtering unit.
The main fans are equipped with backward blades of high
aeraulic efficiency and are driven by A.C. asynchronous electric
motors at LV. The speed of the main fans is variable and
controlled through inverters.
A plenum, made of concrete, is designed to receive the
cleaned gas from the bag filter and equally distribute it to the
main fans. In this way the turbulence created by the main fans
are reduced improving their efficiency and decreasing the
pressure drop of the whole system.
A stack installed over the concrete plenum is designed to discharge the cleaned gases into the
atmosphere. To reduce the noise level, the stack diameter is sized according to a gas speed of
approx. 18 m/sec.
A set of radiant ducts and collectors are foreseen to connect the bag filter outlet with the
concrete plenum, the plenum with the main fan inlets and the main fan outlets with the stack.
A special silencer is installed between each main fan outlet and the stack to further reduce the
noise level at the required value.
18. DSS FTP PROJECT
DUST HANDLING
The dust and particles collected in the various
generation points of the FTP are evacuated in
different ways depending from location.
The dust and heavy particles collected in the
combustion chamber have to be removed when the
EAF is not in operation by means of a bob-cat which
can enter through the water-cooled door.
The natural cooler hopper is fitted with a chain
conveyor and a rotary valve to discharge the collected
dust into skip box.
Similar to the natural cooler, also the axial cyclone hopper discharges the dust via a rotary valve
directly into skip box.
The bag filter is designed with pyramidal hoppers and the dust is removed via a conveyor
system, which transfer the dust till a dedicated storage silo located in an elevated position. The
silo is fitted with level sensors, a manual damper, a vibrating bottom and a rotary valve to
discharge the dust on trucks.
In connection with the natural conditions of an arrangement of FTP, the penthouse of filter is
provided in warm building designs.
DSS FTP PROJECT
CANOPPY HOOD
The canopy hood is placed on the top of the building roof above the EAF and has the purpose to
collect the emissions generated during charging & tapping phases of the EAF. Besides, it has the
duty to ventilate the building during the EAF power-on phase and to such the necessary dilution air
to finally cool down the primary emission temperature before to be processed by the filtering unit.
The shape and volume of the canopy hood depends on several factors, such as:
•distance between EAF mouth and bottom line of the canopy hood
•EAF shell diameter
•position of the EAF in the bay
•geometrical shape of the building roof.
The canopy hood is designed to allow an
adequate “ resident time “ of the fumes during
the EAF most critical operating conditions (i.e.
charging and tapping). Another important factor
taken in due consideration for the canopy hood
design is to avoid the “flow back” phenomena. In
fact, proper dimensioning of the canopy hood
can give enough volume to destroy kinetic
energy of downward fumes.
19. DSS FTP PROJECT
PELLETIZER
The pelletizing machine transforms the
dust collected by the bag filter into
nodules through the addition of a binder
(water), which is sprayed in a rotary
plate. The pellet forms owing to their
rolling on the raking plate of the
pelletizing machine, which is put in slow
rotation. Thanks to the raking position of
the plate and to the material moving, the
greater parts get to the surface while the
smaller parts pass to the lower beds.
As soon as the plate is full of pellets (already formed), these pass over its rim and reach the
discharge chute.
The system includes also a hopper to be located underneath the pelletizing machine and
designed to receive and store the pellets; the hopper is fitted with sliding door for pellet discharge
on trucks; the sliding door is driven by a hydraulic mechanism fed by a dedicated power pack.
CVS
QUALITY MANAGEMENT
QUALITY IS NOT ONLY OUR
POLICY BUT OUR
PHILOSOPHY
20. CVS
GENERAL POLICY
WE BELIEVE OUR KNOWLEDGE
WE FEEL OURSELVES IN THE CORE OF STEEL
FTP REFERENCES
Plant capacity
Year of
Nr. Customer Country Location/site Technology
start-up
(m3/h)
1 NIKSIC Montenegro Niksic 1.200.000 Pulse-jet FF 2009
2 BILECIK DEMIR CELIK Turkey Bilecik 500.000 Pulse-jet FF 2009
3 TOSCELIK Turkey Iskenderun 2.300.000 Pulse-jet FF 2009
4 ENERGOMASSPETSTAL Ukrain Kramatorsk 1.000.000 Pulse-jet FF 2009
5 SOCIETE UNIVERS ACIER Morocco Casablanca 2.000.000 Pulse-jet FF 2009
6 Egypt Alexandria 1.400.000 Reverse-air FF 2009
ALEZZ STEEL AL DEKHILIA
7 TAYBAH STEEL CO Egypt Al Mansura 600.000 Pulse-jet FF 2008
8 COJSCO Jordan Amman 600.000 Pulse-jet FF 2006
9 YESILYURT DEMIR CELIK AS Turkey Samsun 2.000.000 Pulse-jet FF 2006
10 CER ÇEL K ENDÜSTR A. . Turkey Izmir 1.200.000 Pulse-jet FF 2006
11 JORDAN IRON & STEEL CO. Jordan Amman 150.000 Pulse-jet FF 2005
12 JORDAN IRON & STEEL CO. Jordan Amman 150.000 Pulse-jet FF 2005
13 NURSAN METALURJI AS Turkey Iskenderun 1.000.000 Pulse-jet FF 2005
14 CER METAL AS Turkey Izmir 1.500.000 Pulse-jet FF 2005
21. Thank You For Your Patience
www.cvs.com.tr
CVS Makina. Company Presentation
