DNEPROSPETSSTALFUME TREATMENT PROJECT DESCRIPTION

-Design-Manufacturing

- Erection- Training

- Consultancy-Innovation- Process

Development

Offices:- CVS Headquarter

(Turkey)- CVS Europe (Italy)

- CVS Egypt- CVS Ukraine

- CVS Iran

info@cvs.com.tr www.cvs.com.tr

CVS MAKINA - Company Presentation

CVS MAKINA - Company Presentation

CVS provides plants & equipment for minimills,also in “turn-key” solution.

CVS covers the complete design andmanufacturing activities for green-field projectsas well as revamping/upgrading of existingplants and equipment.

CVS manufactures spare parts & componentsfor meltshops & rolling mills.

CVS provides technical assistance andconsulting service to steel production.

Quick Info

CVS MAKINA - Company Presentation

CVS headquarter is placed in the industrialregion of Gebze, just east of Istanbul, closeto many major ports

Our modern facilities consists of more than40,000 sqm of closed area and a land ofadditional approx. 40,000 sqm

CVS workforce is formed by over than 500specialized workers and engineers with amodern machinery park to undertake eventhe most challenging projects.

Over than 200 engineers and administrativeemployees are involved in the design andmanagement of the projects.

CVSWhy FTP Is Important?

Why FTP Is Important?

CVSWhy FTP Is Important?

Why modern dedusting systems are crucialDust Emission - 10 to 25 kg/ton steel.

The most important goals arehigh reliability,strict compliance with prescribed

threshold valuesreasonable energy consumption.

CVS AdvantagesCost-efficient productionMaximized productivityLow consumption levelsShort delivery timesConsistently high availabilityFlexibility of charge materialPreparation for future environmental

requirements

CVSWhat FTP means for EAF?

In the field of environmental protectioninside the electric steel meltshop, a veryimportant application is the collectionand treatment of the primary fumesproduced by the EAF process andescaping from the IV hole on furnaceroof. The emission flowrate,temperature, heat load and compositionare continuously and suddenly changingduring the power-on phases. The mainpollutant generated by the EAF processare the fine dust of iron oxide and otherheavy metals, volatile compounds, butalso the quantity of CO and VOC arehigh.

CVSWhat to consider during decision?

-To achieve high reliability and favorableoperating costs requires the right design.-The more cleanly the process parameters areadapted to one another and the more preciselythe design is tailored to the up-streamaggregate, the more smoothly the operationwill run.-Long-lasting, low-maintenance componentsvirtually eliminate unplanned downtimes.

A dedusting system requires sensibleinvestments. That is why it is so important forthe system to be able to accommodate futureexpansions of production and potentiallystricter environmental regulations - withoutrequiring significant modification andconversion costs. And for the same reason,you need a plant layout that also offersflexibility for the future.

CVS - FTPWhy to Choose CVS

CVSWhy to choose CVS?

CVS offers the entire spectrum of dedusting technology from a single source, always inclose collaboration with our customer's steel production plant specialists. This is ourapproach for creating perfectly coordinated, economically viable solutions

Good reasons for our dedustingsolutions•Guaranteed compliance withagreed-upon limit values•Tailored dedusting units usingcomprehensive mini-mill expertise•Future emission requirements arealready taken into account in theplant layout•Problem-free operation with lowservice requirements•Turnkey solutions from a singlesource - with one contact, and oneperson in charge

CVS - FTPDedusting solutions for your EAF steel mill?

Clean EnvironmentHigh availability, high reliability andguaranteed elimination of residues such asdioxin from an electric arc furnace. In otherwords, you produce steel while we makesure your systems and your environmentstay clean.Maintenance? Short, planned and efficientRobust components, high-qualityworkmanship and the right design keepmaintenance to a minimum. Our systemsalso allow bags to be changed duringoperation - another way we contribute tohigh availability.Equipped for future demands todayCVS designs your system to harmoniouslyaccommodate any future expansions withno long downtimes or start-up problems.Thus, with your initial investment, we've putyou on the right track to effectively limitingsubsequent costs later on

CVS - FTPAUTOMATION

Smooth operation - fullyautomatedCVS automation ensuresflexible, secure operation, ahigh degree of safety forpeople and machinery andhigh efficiency over the entirelife-cycle of the system.Advanced solutions, such asan inverter for large drives,contribute to decreased energycosts by allowing output andenergy consumption to becontinuously adapted toproduction demands.

CVS - FTPAUTOMATION

Operation of complete dedusting systemis syncronised by automation system.Distribution of flow to primary andsecondary section of EAF is controlled bytwo dampers located on the linesactuated automatically by automation.

Damper position and main fan speedsaccording to 5 main modes of furnaceoperation can be changed by HMI in FTPcontrol room.

Additionally, fan speed is adjusted duringmelting phase according to the value comingfrom pressure transmitter measuring thepressure inside combustion chamber.

CVSConverter Off-Gas System

WE FOLLOW LAST TECHNOLOGIESWHEN WE MANUFACTURE OFF GASSYSTEMS

CVS -Converter Off-Gas System

RESPECT TO THE NATURE

DSSCOMPANY PROFILE

A leader in production of special steel products, Dneprospetsstal (DSS) is based inZaporozhye, Ukraine, and employs about 6 200 people.Originally founded as a state-run enterprise in 1932, today Dneprospetsstal’s activities coverthe design, manufacture and distribution of stainless, tool, high-speed (including powdermade steel), bearing and alloy structural steel products.DSS’ products are used in the manufacture of machinery parts, tools for metal and alloymachining, seamless pipes and bearings.DSS enjoys a unique position as a high added-value producer. The company’s location inUkraine gives it a favorable geographical advantage, placing it in proximity to two of itslargest consumer regions: the CIS and the EU. With partners and distributors in more than15 different countries, DSS casts a wide net over world markets; its products are used andsold in over 60 countries.Dneprospetsstal aims at retaining leadership in the domestic market and expansion of itspresence in the markets of Russia, Europe, America and Asia using existing and newdistribution channels.The Company also strives for entering into strategic alliances and finding partners forcooperation in the field of subsequent metal processing.

DSSPRODUCTION CHART

Dneprospetsstalproduces morethan 800 gradesand 1000 cross-sections.DSS manufacturingprocess is anoptimalcombination ofdifferenttechnologicalprocedures, whichprovide making ofhigh qualityproducts withdesired properties,

DSSECOLOGICAL VISION

GoalTo create anenvironmentallysafe business.

ResultInvesting significantfunds annually intoenvironmentalprojects likepurification equipmentand the introduction ofenergy savingtechnologies.

IdeaEnvironmentalprotection meansconcern aboutpeople's health

DSSFTP DECISION

Dneprospetsstal constantly develops and modernizes production facilities, new technologiesdeveloped and up-to-date equipment implemented result in the highest quality productperformance.

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.

DSS FTP PROJECTPLANT PHOTO

DSS FTP PROJECTGENERAL 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 & negativepressure type;•Exhausting of the cleaned gases by means of two main ID fans driven by AC motors withinverter;•Emission into the atmosphere of the cleaned gases by means of dedicated stack sized.

Design considers following workingprofile:

Melting phase•EAF in melting phase (roof closed,primary fumes suction line open);•Suction from the canopy hood toprovide meltshop ventilation and primaryfumes cooling;•LF in heating phase;•MHS in operation.

Charging/Tapping phase•EAF in charging/tapping phase (roofopen, primary fumes suction lineclosed);•Suction from the canopy hood;•LF in heating phase;•MHS in operation.

DSS FTP PROJECTDESIGN

DSS FTP PROJECTPROCESS FLOWSHEET

DSS FTP PROJECTGENERAL LAYOUT

DSS FTP PROJECTSECTION VIEW

DSS FTP PROJECTDESIGN VALUES

EAF secondary emissions (canopy hood):•Suction capacity (tapping/charging): 800.000 Nm3/h @ 80 oC•Ventilation capacity (melting): 370.000 Nm3/h @ oC•Actual fume flowrate (tapping/charging): 1.030.000 m3/h•Actual fume flowrate (melting): 440.000 m3/h•Hot fumes spreading velocity approx. (charging): 2.20 m/sec

EAF primary emission (melting phase):•Fume suction capacity: 45.000 Nm3/h @1.600 oC•Fume temperature at cooler outlet: 300 oC

Ladle Furnace•Suction capacity: 37.000 Nm3/h @ 150 oC•Actual fume flowrate: 60.000 m3/h•2 LF total suction capacity: 74.000 Nm3/h•Temperature at suction duct inlet:90 oC•2 LF Actual fume flowrate: 110.000 m3/h

Material handling system emission•Suction capacity: 50.000 Nm3/h @ 50 oC•Actual fume flowrate: 60.000 m3/h

DSS FTP PROJECTBAG FILTER DESIGN

Total design capacity: m3/h 1.200.000Max. working temperature: °C 120Compartments: nr. 16Bag cleaning system: pulse jet off-lineCompartment off-line: nr. 2Total filtering surface: m² 14.855Net filtering surface: m² 12.998Clean gas dust content: mg/Nm³ 20Filter headers: nr. 16Blowing electro valves: nr. 264 – 2 incFiltering bags: nr. 4.224 pcsFiltering bag material: polyester needle feltFiltering tissue weight: g/m² 500Filtering bag dimensions: mm 160 x 7.000

DSS FTP PROJECTEAF PRIMARY EMISSIONS

The EAF primary emissions are controlled by a set of water cooled ducts (WCD) and radiant orsingle-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 apneumatically adjustable sliding sleeve. The purpose of the sliding sleeve is to regulate the gapbetween the IV hole elbow (part of the EAF roof) and the consequent WCD line. Through thisgap the necessary external air is sucked to dilute the primary gas and to permit the COcombustion in the chamber.

A combustion chamber made of water-cooled panels and concrete / refractory in the bottompart; it is sized to guarantee suitable retention time for CO full combustion and to allow forvelocity reduction to enable heavy particles to settle.

A set of water-cooled ducts (WCD) are designed to cool down the hot gases coming from thecombustion 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 mixingwith the EAF Secondary Emission line. The Natural Cooler consists of a bundle of radiant ductsof suitable diameter to avoid clogging.

A set of radiant ducts (SWD) of single walled type are foreseen to convey the gases from theWCD to the Natural Cooler.

A regulation damper of multi-flaps type driven by electric actuator designed to adjust thesuction flow in the line.

DSS FTP PROJECTEAF SECONDARY EMISSIONS

The EAF Secondary Emissions are controlledthrough the following components:

A large canopy hood installed on the top of thebuilding roof and designed to collect the EAFemission during charging / tapping phases and tosuck the necessary dilution air to finally cool downEAF primary gases to reach a temperatureacceptable by the filtering unit. The canopy hoodvolume and shape are designed to allow anadequate “resident time” of the emission during theEAF most critical operating conditions.

Two collectors of “trombone” type are installedinside the canopy hood to improve the internalsuction efficiency.

A main duct line is foreseen to convey the secondary emissions from the two collectors to thefiltering 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 inany operating conditions.

A safety damper, pneumatically actuated for a quick response when gas temperature exceed themaximum continuous working temperature of the filtering unit (about 130°C).

DSS FTP PROJECTLF & MHS EMISSIONS

The control of the LF emissions isperformed through the followingcomponents:A side-draft hood set-up on LF roof topand designed to collect the primarygases generated by the LF (this hoodis part of the LF its self).A set of radiant ducts of single walledtype designed to convey the gasesfrom the side draft hood to the mixingpoint with the EAF secondary emissionmain ducts.A booster fan of centrifugal type isprovided to compensate the losses inthe duct, thus allowing an efficientsuction. The fan is driven by a LVmotor and is fitted with a regulationdamper actuated by electric actuator.

The following equipment carries out thecontrol of the emission generated by theMaterial Handling System:•A set of local suction hoods (to be definedand sized by the Material HandlingSystem supplier) to be located as close aspossible to the emission sources.•A set of radiant ducts to connect the localhoods with a common duct and thenconnected with the EAF secondaryemission main ducts.3. A booster fan of centrifugal type isprovided to compensate the losses in theduct, thus allowing an efficient suction.The fan is driven by a LV motor and isfitted with a regulation damper actuated byelectric actuator.

DSS FTP PROJECTFILTERING UNIT

The emissions filtration is carried out through one negative pressure bag filter with off-line pulse-jetbag cleaning design. This type of filter works in under-pressure with the main fans located afterwardand is equipped with an automatic bag cleaning system based on the use of compressed air jet intothe bags.The high efficiency of the bag cleaning system requires a reduced volume of injected air at lowpressure, thus reducing air consumption and pressure drop.

The main advantages of suggesting filtersare summarized as follows:- reduced overall filter dimensions, thanks toa filtering surface far lower than that of afilter cleaned by a reverse air operation;- fans located downstream the filter,consequently high efficiency impellers canbe used thanks to the small dust content inthe treated gas; no out of balance risk isfaced;- reduce pressure drop thus low energy andcompressed air consumption;- easy maintenance and bags replacing.

Huge flowrate calls for pulse jet filter which aresuction-type filters, equipped with compressed airautomatic bag cleaning system. The filter itself iscomposed of 2 parallel lines, made up of severalcompartments containing a fixed number of bags.Each compartment consists of a “raw gas”chamber below and a “clean gas” chamberabove divided by the bag supporting plate. Thelower chamber composes the filter body, containsthe filtering bags and the dust collecting hoppers.The upper chamber contains the injectors for thecompressed air distribution to the bags forcleaning purpose.

DSS FTP PROJECTBAG FILTER

The two chambers are connected to the central collector respectively to the gas inlet and outlet bymeans of separation dampers. Dampers for lower chambers are manually actuated, being utilizedin closed position as an additional safety in the event of maintenance or inspection; the dampers ofthe upper chambers, instead, are provided with pneumatic actuators, being automatically closedwhile 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 composedof one distributor per row of bags, completed with compressed air feeder to each bag.

DSS FTP PROJECTEXHAUSTING SYSTEM

The suction and exhaust of the various emissions is performedby the following equipment:

Three centrifugal fans located downstream the filtering unit.The main fans are equipped with backward blades of highaeraulic efficiency and are driven by A.C. asynchronous electricmotors at LV. The speed of the main fans is variable andcontrolled through inverters.

A plenum, made of concrete, is designed to receive thecleaned gas from the bag filter and equally distribute it to themain fans. In this way the turbulence created by the main fansare reduced improving their efficiency and decreasing thepressure drop of the whole system.

A stack installed over the concrete plenum is designed to discharge the cleaned gases into theatmosphere. To reduce the noise level, the stack diameter is sized according to a gas speed ofapprox. 18 m/sec.

A set of radiant ducts and collectors are foreseen to connect the bag filter outlet with theconcrete 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 thenoise level at the required value.

DSS FTP PROJECTDUST HANDLING

The dust and particles collected in the variousgeneration points of the FTP are evacuated indifferent ways depending from location.

The dust and heavy particles collected in thecombustion chamber have to be removed when theEAF is not in operation by means of a bob-cat whichcan enter through the water-cooled door.

The natural cooler hopper is fitted with a chainconveyor and a rotary valve to discharge the collecteddust into skip box.

Similar to the natural cooler, also the axial cyclone hopper discharges the dust via a rotary valvedirectly into skip box.

The bag filter is designed with pyramidal hoppers and the dust is removed via a conveyorsystem, which transfer the dust till a dedicated storage silo located in an elevated position. Thesilo is fitted with level sensors, a manual damper, a vibrating bottom and a rotary valve todischarge the dust on trucks.

In connection with the natural conditions of an arrangement of FTP, the penthouse of filter isprovided in warm building designs.

The canopy hood is placed on the top of the building roof above the EAF and has the purpose tocollect the emissions generated during charging & tapping phases of the EAF. Besides, it has theduty to ventilate the building during the EAF power-on phase and to such the necessary dilution airto 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 anadequate “ resident time “ of the fumes duringthe EAF most critical operating conditions (i.e.charging and tapping). Another important factortaken in due consideration for the canopy hooddesign is to avoid the “flow back” phenomena. Infact, proper dimensioning of the canopy hoodcan give enough volume to destroy kineticenergy of downward fumes.

DSS FTP PROJECTCANOPPY HOOD

The pelletizing machine transforms thedust collected by the bag filter intonodules through the addition of a binder(water), which is sprayed in a rotaryplate. The pellet forms owing to theirrolling on the raking plate of thepelletizing machine, which is put in slowrotation. Thanks to the raking position ofthe plate and to the material moving, thegreater parts get to the surface while thesmaller parts pass to the lower beds.

As soon as the plate is full of pellets (already formed), these pass over its rim and reach thedischarge chute.The system includes also a hopper to be located underneath the pelletizing machine anddesigned to receive and store the pellets; the hopper is fitted with sliding door for pellet dischargeon trucks; the sliding door is driven by a hydraulic mechanism fed by a dedicated power pack.

DSS FTP PROJECTPELLETIZER

CVSQUALITY MANAGEMENT

QUALITY IS NOT ONLY OUR

POLICY BUT OUR

PHILOSOPHY

CVSGENERAL POLICY

WE FEEL OURSELVES IN THE CORE OF STEEL

WE BELIEVE OUR KNOWLEDGE

FTP REFERENCES

Nr. Customer Country Location/sitePlant capacity

Technology Year ofstart-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 ALEZZ STEEL AL DEKHILIA Egypt Alexandria 1.400.000 Reverse-air FF 2009

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

CVS Makina. Company Presentation

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