System combines the advantages of 100% scrap preheating and continuous scrap feeding through its chambers, without the need of EAF roof opening. EPC prevents totaly, any dust emission and heat loss during furnace charging stage, as it is the case normally for other operations. The EPC-EAF is a new generation, economical and environmentaly friendly Electric Arc Furnace. Considerable reduction in electric energy consumption, increased productivity, meeting strict environmental regulations, less dust load within the melt shop, flicker reduction& harmonic disturbance reduction are some of the important features of the new and superior EPC system.
Repurposing LNG terminals for Hydrogen Ammonia: Feasibility and Cost Saving
NEW GENERATION IN PRE-HEATING TECHNOLOGY
1. KR
Tec
E N V I R O N M E N TA L P R E H E AT I N G
&
CONTINUOUS CHARGING SYSTEM
(EPC)
2. KR Tec C O M PA N Y P R E S E N TAT I O N
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 Development
CVS POLAND CVS IRAN CVS INDIA CVS S.KOREA CVS SINGAPORE CVS USA CVS GREECE
Warsaw Tahran Pune Seoul Singapore New York Athens
info@cvs.com.tr www.cvs.com.tr
3. KR Tec C O M PA N Y P R E S E N TAT I O N
CVS provides plants & equipment for
minimills, also in “turn‐key” solution.
CVS covers the complete design and
manufacturing activities for green‐field projects as
green field
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.
4. KR Tec C O M PA N Y P R E S E N TAT I O N
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
50,000sqm
50 000sqm of closed area and a land of additional
approx. 50,000sqm
CVS workforce is formed by over than 750
specialized workers and engineers with a modern
machinery park to undertake even the most
challenging projects.
g gp j
Over than 270 engineers and administrative
employees are involved in the design and
management of the projects.
5. KR Tec EPC SYSTEM
CVS MAKINA has a 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.
6. KR Tec 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.
7. KR Tec 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.
8. KR Tec 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.
9. KR Tec EPC SYSTEM
BENEFITS REGARDING ENVIRONMENT
Charging with closed system
h h l d
Minimum fume during scrap charging
Cleaner working area
30% less off gas
30% less off gas
30 % less dust at the filter
Less noise (melting of preheated scrap)
Respect of most environmental standards
Respect of most environmental standards
10. KR Tec EPC SYSTEM
FEATURES
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
11. KR Tec EPC 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.
13. KR Tec 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
16. KR Tec EPC CHARGING HOPPER IN
CHARGING POSITION PREHEATING POSITION
17. KR Tec EPC TELESCOPIC FEEDER IN
STA RT P O S I T I O N FRONT POSITION
18. KR Tec PROCESS 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
19. KR Tec 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
20. KR Tec PROCESS STEPS OF EPC
Preheating inside EPC
‐Start feeding of preheated scrap after tapping
‐Pre‐heating chamber half empty hopper can move backward to waiting
position
21. KR Tec PROCESS STEPS OF EPC
Preheating inside EPC
‐Scrap bucket in waiting position
‐Continuous feeding of scrap during power on
‐Control of preheating scrap temperature with by‐pass regulation flap
22. KR Tec PROCESS STEPS OF EPC
Charging of Upper Hopper EPC
‐Start feeding of preheated scrap
‐Opening of sliding gate on top
‐Charging of next bucket into charging hopper
23. KR Tec PROCESS STEPS OF EPC
Parking Position of EPC
‐EPC system is moving backward on wheel mechanism underneath only for
maintenance purpose
24. O P E R AT I O N A L C Y C L E
KR Tec DIAGRAM WITH 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
25. LIQUID STEEL LEVEL
KR Tec DURING CYCLE WITH EPC
140
EAF
120 C A PA C I T Y
100 TON
100 TRANSFORME
R C A PA C I T Y
80
LIQUID STEEL
60
SCRAP WEIGHT IN
FIRST CHAMBER
40
SCRAP WEIGHT IN
SECOND
REPARATI
EPARATION
20 APPING CHAMBER
1 HEAT CYCLE
PR
PRE
TA
-
0 5 10 15 20 25 30 37 42 47 52
26. C O M PA R I S O N O F
KR Tec PRODUCTIVITY
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)
27. C O M PA R I S O N O F
KR Tec O P E R AT I O N E 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
Consumptio Consumptio
Unit EUR n EUR/t n 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
(100 TON – 100 MVA FURNACE)
28. C O M PA R I S O N O F
KR Tec CONVERSION COSTS
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)
29. KR Tec 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)
30. EPC SYSTEM
KR Tec POWER FLUCTIONS
VOLTAGE, CURRENT AND POWER FLUCTUATIONS;
BEFORE AND AFTER SCRAP PREHEATING
31. KR Tec 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
32. KR Tec REFERENCES ‐ 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 2005
33. KR Tec R E F E R E N C E S ‐ S E C O N D . M E T.
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 1998
34. KR Tec REFERENCES ‐ 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 8 m 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
36. KR Tec REFERENCES ‐ 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
37. KR Tec REFERENCES ‐ OFF GAS
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
38. KR Tec R E F E R E N C E S ‐ S PA R E PA R T S
Customer Country Customer Country Customer Country
ACCIAIERIE VALBRUNA Italy EKINCILER DEMIR CELIK Turkey MITTAL SKOPJE
MITTAL SKOPJE Macedonia
AL RAJHI Saudi Arabia ELECTROSTAL Ukraine MOBARAKEH STEEL Iran
AL TUWAIRQI Saudi Arabia ELWOOD STEEL Belgium NATIONAL STEEL Saudi Arabia
ALL EZZ GROUP Egypt ENGINEERING STEEL
Belgium NOVOROS METALL LTD. Russia
ALSTOM POWER Italy BELGIUM
NURSAN METALURJI AS
NURSAN METALURJI AS Turkey
AMK ALCHEVSK Ukraine ERVIN AMASTEEL Belgium
QATAR STEEL Qatar
ARCELOR MITTAL RUHRORT Germany ETEAM Italy
REVYAKINO Russia
ARCELOR MITTAL TEMIRTAU Kazakhstan FERRIERE NORD Italy
ARCELORMITTAL SALZGITTER FLACHSTAHL Germany
France FOLDER Denmark
DUNKERQUE SHARQ SOHAR Oman
GERLAFINGEN Switzerland
ARCELORMITTAL HAMBURG Germany SIDENOR SA Greece
GORKY STEEL Russia
ARCELORMITTAL SKOPJE Macedonia SIDERURGICA BALBOA Spain
G‐STEEL Thailand
ARCOSTEEL Egypt SIVAS DEMIR CELIK Turkey
HALYVOURGIA THESSALIAS SA
HALYVOURGIA THESSALIAS SA Greece
BAKU STEEL Azerbaijan SOHAR STEEL Oman
HALYVOURGIKI Greece
BENTELER Germany SONASID Morocco
INDUSTRIAS NACIONALES Dominican Rep.
Bosnia SOVEL Greece
BH STEEL IZMIR DEMIR CELIK Turkey
Herzegovina
SUEZ STEEL gyp
Egypt
CARINOX Belgium JORDAN IRON & STEEL CO.
JORDAN IRON & STEEL CO Jordan
J d
SWISS STEEL Suisse
CEMTAS Turkey KAPTAN DEMIR CELIK Turkey
THAME STEEL United Kingdom
CER METAL AS Turkey KARABUK DEMIR CELIK Turkey
TIMKEN USA
CHARTER STEEL USA KOMOTEK Bulgaria
TOSYALI HOLDING
TOSYALI HOLDING Turkey
CMC SISAK Croatia KREMIKOVSKI Bulgaria
UNITED IRON & STEEL MGF. CO. Jordan
COJSCO Jordan KURUM STEEL Albania
YESILYURT Turkey
CORUS Holland MAKEEVKA STEEL WORKS Ukraine
ZELJEZARA NIKSIC AD Montenegro
DUFERCO Belgium MED STEEL Syria
39. Yo u r O n e ‐ S t o p
Solution Provider for
Meltshops & Rolling Mills
Ecological Solutions for
Electric Steel Making KR Tec