cvs general ion 09

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.

CVS Makina. Company Presentation

MELTSHOP DESIGN

From Water Cooled Panels to complete Electric Arc Furnaces, from Ladles to completeLadle Furnaces, from Tundishes to complete Continuous Casting Machines, from Ductsto complete Fume Treatment Systems and from Engineering Services to Turn-KeyPlants, CVS offers economically viable solutions at European standards.

CVS - E.A.F.Design Concept

• CVS has more than 50 Electric ArcFurnaces supplied worldwide

• Furnace size from 12 to 180 tappedsteel

• Some EAF futures:– AC type– EBT tapping system– conductive or traditional

electrode arms– original roof lifting design– full platform & split shell design

CVS - EAFDesign Main Objective

Low production costs

Higher process flexibility.

Increasing productivitywhile improving energyefficiency.

mproving the quality ofthe finished product.

Meet environmentalrequirements at aminimum cost.

Better coordination ofprocess/environmentalrequirements

CVS - EAFTypical Furnaces

The EAF is of “Full Platform” type i.e. with electrode lifting column supportand the roof lifting and turning machinery mounted on the tilting platform.

The main design features are as follows:

The cradles are arranged so as to guarantee a tilting opposite to thetapping side in case of a hydraulic failure.Furnace shell of split type.Rigid design in order to avoid distortion due to mechanical or thermalstresses.Curved shape in order to guarantee optimal refractory performance.Shell upper part of cage type and water-cooled panels with cover plates inorder to minimise air inlet.Eccentric Bottom Tapping, EBT, with hydraulically operated swivelling gatemechanism.Roof hung in two points allowing to optimal roof closing during melting.

CVS - E.A.F.Mechanical Design Features – 1/2

CVS - E.A.F.Mechanical Design Features – 2/2

Mechanical design features - Continued

Electrode lifting columns and electrode arms of stiff design allowing forfast response electrode position control.Hydraulic system designed for fast furnace movements and high speed-fast response electrode position control.The electrode hydraulic regulation uses counter pressure in order tobalance out the weight of the column, arm and power cables.

CVS - E.A.F.Design Benefits

Gantry design for self-supporting furnace roofPrismatic roller-guide system for electrode mastsHigh-current-conducting electrode arms in copper-clad box designState-of-the-art electrode control systemSplit-shell designCopper or combi-panels with high-speed cooling water flowOxygen and carbon injectionAll bottom tapping systems EBT, EO-EBT, RBT, OBT)Special hot-metal charging facilitiesContinuous DRI/HBI feeding systems

Main benefitsIncreased productivity due to shortest melting and idle timesHigh power input (up to 1 MVA/t)High-impedance furnaceArc voltage up to 1,500 VProven low-consumption values energy, electrodes, refractories, etc.)Low tapping temperatures and minimum slag carry-overMinimum maintenance with the use of heavy mill-type componentsHighest flexibility with respect to charge materials

CVS - EAFChemical Energy System Concept

CVS has special oxy-burner system for higher productivity

The injection system consists of a set of jet burners installed on the EAF shell.The jet burners are supersonic oxygen injectors combined with a hydrocarbonburner, all in the same housing.

Three jet burners are installed in the upper shell’s side wall, while the forth oneis located in the EBT area. The functions of the injection system are :

decarburization of the steel baththermal energy inputformation of foaming slagreduced need of charge carbon with the scrapthe thermal energy is efficiently transferred to the bath with less fuel, lower off-

gas temperature and much better control of CO emissions.

CVS - EAFBurner Design Concept

The location and the direction of the burners are determined to reduce the coldspots effect generated by the three-phase arc of the furnace, thus obtaining aneven and faster melting.

CVS - EAFBurner Positioning Inside Furnace

The lance manipulator for the Electric Arc Furnace is primarily designed forsafe oxygen injection. As well, solid materials like Carbon can be given fromburner case.

The Carbon injection in the bath have demonstrated of outmost importance towork with proper foaming of the slag and to obtain recarburisation of liquid steelbath if required to control bath composition.

CVS - EAFBurner Advantageous

• Higher burner efficiency (cleaner walls, reduction of electric energyconsumption)

• Higher supersonic oxygen efficiency (reduction of electrode consumptionand increase of refractory delta life)

• Higher burner power (up to 8 MW burner and 4000 Nm3/h of supersonicoxygen)

• Carbon injection in the slag (CH4 + N2 cooled) or above the slag (air cooled)

CVS - EAFBurner Positioning Inside Furnace

• Very low installation in water cooled copper box• Refractory saving by cooling block• Long life (8-18 months)• Fast substitution time• Flame shape control• De-Luxe gas valve stand• Improve Metallic Yield• Very flexible automation

CVS - EAFBurner Flame Shape Management

Burner Flame

High Flame

Supersonic Flame

EBT Burner Flame

CVS - EAFSlag Foaming

Foaming slag is used to increase the thermalefficiency of the furnace during the refiningperiod, when the side walls are fully exposedto the arc radiation.

A foaming slag will rise and cover theelectric arcs, thus permitting the use of ahigh tap setting without increasing thethermal load on the furnace walls.

In addition, an electrical arc covered by a foaming slag will have a higher efficiency intransferring the energy into the steel phase.

CVS -Slag Foaming

Slag foaming is obtained byinjecting oxygen into the liquidsteel, where mainly iron isoxidized according to thereaction:

O2 + 2 Fe = 2 (FeO)

Carbon powder is then injectedsimultaneously into the slagphase where iron oxide isreduced.

(FeO) + C = Fe + CO (g)

The resulting CO gas is a criticalcomponent in order to obtain afoaming slag.

CVS - EAFPanel Design Example

CVS have big experience for manufacturing of Furnace panels made of copper andsteel.

Special testing methods is applied before shipment.

CVS - EAFTypical EAF Layout

CVS - EAFTypical 3-D View

CVS - EAFTypical 3-D View

CVS - EAFTypical Section View

CVS - EAFRoof Lifting Operation

CVS special design of Roof Liftingsystem yields for easy and safeoperation.

CVS - E.A.F.Auxiliaries

CVS - SECONDARY METALLURGYLF. Concept

The operation executed at the ladle furnace isan essential part of the secondary metallurgytreatment, such as refining, adjustment ofliquid steel temperature and chemicalcomposition with the target to increase qualityof steel.

CVS - SECONDARY METALLURGYLF. Advantages

The advantages of a ladle furnace can be defined as follows :

•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

CVS - SECONDARY METALLURGYLF Design Advantageous

Water-cooled ladle roof equippedwith indirect fume collecting hoodto reduce steel oxidation

Roof lifting mechanism viahydraulic cylinder

Electrode arms with reducedelectrode pitch diameter

Water-cooled secondary circuitand water cooled flexible cables

Electro-hydraulic electroderegulation

The Ladle Furnace is conceived for reheating the steel in the ladle placed on aladle car and will be designed and built according to the most modern techniques inthe field and will be in particular provided with:

Water-cooled secondary circuit and water cooled flexible cables

CVS - SECONDARY METALLURGYVD / VOD Plant

The purpose of secondary metallurgical steel treatment under vacuum conditions isto produce high-purity steel having following properties:

low content of harmful elements such as sulphur, phosphorus, trace elements and/orcarbon,

lowering of oxygen, nitrogen and hydrogen gases dissolved in the steel,

as well as major improvements of steel purity, including shape control of non-metallicinclusions.


PURPOSE• H removal• N removal• S removal• C removal (VOD)

RESULTS• H contents < 1 ppm• N contents -30/50 %• S contents -80/95 %• C contents < 20 ppm

PROCESS•Temperature loss during

vacuum treatment

LAYOUT• Longitudinal section• Vacuum pump

DESIGN FEATURES• Dimensioning of vacuum tank• Vacuum hopper• Dust separator

VACUUM PUMP FUNCTION• Function of a steam ejector• Compression of off-gas with ejectors inseries• Intermediate condensation of motivesteam• Waterring pumps• Global function of ejectors andcondensers• Process flow diagram 5-340 WR• Suction capacity of pump 5-340 WR


Hydrogen Removal

The final hydrogen content of a heat depends on the pressure of vacuum vessel, the amountof the purging gas and the CO-gas development.

Even fully killed heats can be treated due to intensive degassing supported by lift gas. Forlowest hydrogen levels the pressure must be lower than 1 mbar with according treatmenttimes of 15 - 20 min depending on the starting level.

Nitrogen Removal

Even in VD-Plants nitrogen removal is preferably carried out. Having low sulphur andoxygen levels this process as well requires low vacuum levels with less than 1mbar forapprox. 15 - 20 min.

Argon is purged by the porous plugs from the ladle bottom with approx. 10 Nl/(min, t steel).


Sulphur Removal

The final sulphur content of a heat depends on the pressure of vacuum vessel, theamount of the purging gas and the amount of synthetic slag added prior to vacuumtreatment start. The EAF furnace slag has to be reduced during tapping to values below orequal to 5 kg/t Steel.

For low sulphur levels the pressure must be lower than 1 mbar with according treatmenttimes of 15 - 20 min depending on the starting sulphur level. Argon purging by the porousplug from the ladle bottom with approx. 10 Nl/(min, t steel) has to be ensured.

Light Treatment (Deoxidation)

The liquid steel will be tapped unkilled or semi-killed from the EAF and partly deoxidisedin the VD-plant.

The deoxidation will occur due to the CO-development by natural decarburisation. Thepressure range depends on the C-O equilibrium and is about 40 - 200 mbar.

After 10 - 12 min treatment the final deoxidation will be carried out with Al or others.Thus large amounts of deoxidation agents can be saved by light treatment.

CVS - SECONDARY METALLURGYVD / VOD Steam Ejector Pumps

Vacuum Ejectors/ Water Ring Waste GasVessel Condensers Pumps Line

Condenser

Booster/ejector

Water ring pump

Vacuum pump system (typical)

Vacuum Vessel


PROCESS

- Modelling of the VOD process

- Optimisation EAF-VOD

- Slag reduction

- Desulphurisation

VOD PROCESS CONTROL

-Calculation functions

- Thermodynamic model

- Example of oxygen blowing

THERMODYNAMICSC - removal at low pCO and high temp

3 3 22 3C Cr O CO Cr % ( *% ) * **

( / . )C f Cr p

a fCr CO

T

Cr O C

2 3 40536 25 63

3310

2 3

EAF

VOD

COST FOR REMOVING C IN EAF AND VOD

OPTIMUM RANGE

CO

ST

0 0.5 1.0CARBON CONTENT


Modelling Of The VOD Process

1520

1540

1560

1580

1600

1620

1640

1660

1680

1700

1720

0 20 40 60 80 100 120 140 160 180 200

Time, minutes

Tem

pera

ture

, C

0.0

0.1

1.0

10.0

100.0

1000.0

Pres

sure

, tor

r

Slagbuilding, AlloyingHeating

OxygenReductionAgents

TrimAdditions

TA

Tap

PREPARATIONIN LF

OXYGEN BLOW SLAGRED

BOILOFF

FINALTRIM

TA

TA



CVS - SECONDARY METALLURGYLadle Inert Gas Use

Homogenisation of The Bath TemperatureHomogenisation of the Bath Chemical

CompositionBetter Mixing Between Steel and SlagsBetter yield of additives (ferroalloys)More Clean steel

a. Refractory material on the ladle bottomb. Porous platec. Porous refractory insertd. Locking equipmente. Gas inlet

CVS - Liquid Steel AuxiliariesLadle and Ladle Cars

CVS - Liquid Steel AuxiliariesLadle Emergency Stirrer Lance

This gas stirring system is designed to feed inert gas through a refractory lance foremergency stirring if the porous plug does not work properly.

The refractory lance is held and plunged into the steel bath by a structure adjacent tothe ladle roof.

CVS - Liquid Steel AuxiliariesLadle Preheaters / Driers

Ladle pre-heater/drier consists ofa circular, concave lida centrally located fuel-air burner.

The burner creates a high-velocity, extended flame, which brings the thermal energydown to the ladle bottom.

The combustion air is generated by a centrifugal fan located in a protected position in theburner stand and led via the cover suspension arm to the burner.

The hydraulic power for lid movements is provided by an independent hydraulic powerpack.

The burner is directly ignited by means of a high voltage device after automatic purgingof the combustion chamber.

CVS - Liquid Steel AuxiliariesLadle Preheaters / Driers

CVS - CCMDesign Concept

CVS - CCMGeneral description

Continuous Casting is the process whereby molten steel is solidified into a"semifinished" billet, bloom, or slab for subsequent rolling in the finishing mills.

Steel from the electric arc furnace is tapped into a ladle and taken to the continuouscasting machine. The ladle is raised onto a turret that rotates the ladle into thecasting position above the tundish. Liquid steel flows out of the ladle (1) into thetundish (2), and then into a water-cooled copper mold (3). Solidification begins inthe mold, and continues through the First Zone (4) and Strand Guide (5). In thisconfiguration, the strand is straightened (6), torch-cut (8), then discharged (12) forintermediate storage or hot charged for finished rolling.


CCM can be designed to produce square billets in the sections between 100 to 160mm2, and blooms between 180 to 260 mm2.

Special designs for beam blank and round sections between 160 to 440 mm can bedone.

Radius of 5-12 meter and mould length of 750-1000 mm can be designed according toproject requirement.

For some special casting, vertical continuous casting application can be considered.

The CCM can be fitted with up to eight casting strands in order to satisfy theproduction schedule given by the EAF.

According to customer request, CCM can be equipped with the necessary modernequipment to produce high quality casted products, such as tundish of delta type toreduce inclusions in the mould, long copper tube to improve primary cooling on thebillet surface, automatic mould level control system, high casting radius to reducestress during unbending, secondary spray cooling divided in three zone for a bettercooling effect and control, walking beam cooling bed for the straightening of the longbillets.


CVS - CCMQuick Nozzle Changer

The Quick Nozzle Change QNC system allows longsequence casting using the same tundish byreplace the tundish nozzle on the fly withoutrequiring substitution of the tundish or castinginterruptions.

CVS - CCMQuick Nozzle Changer Profits

9595,5

9696,5

9797,5

9898,5

9999,5

Material yield

single heatshort sequencelong sequence

Quick nozzle change device in the CCM canincrease the number of heats in sequence:

– Better billet quality thanks tokeeping a constant castingspeed

– Up to 75% of tundish refractoryconsumption saving up to

0,7US$/ton– Up to 80% of metallic losses

reduction due to a reduction ofhead/tail crops and tundish skullsaving up to 0,8US$/ton

– Reduction of tundishmaintenance people because ofReduction by 5 times thenumber of tundish used

– Increase of the metallic yield ofthe caster up to 0.5%

CVS - CCMTypical Sectional View

CVS - CCMTypical Sectional View

CVS - CCMTypical View

CVS - CCMLadle Turret

Serving to support the teemingladle and adjust it to castingposition.

Design for handling up to two fullteeming ladles.

Weighig Load-cells

Emergency Turret Rotation

Different Designs

Ladle CarLadle Rotation ArmLiftible Ladle TurretIndependent Arm Ladle Turret

CVS - CCMTundish Car

Different Designs

Cantilever TypeRail TypeSemi-cantilever TypeLiftable Type

Serving to support the tundishand adjust it to casting position.

Quick nozzle changer system

Adaptable to stopper rodmechanism

Weighig Load-cells

Emergency Translation viaelectric motor

CVS - CCMMould Oscillation

Design Features

- Heavy-duty design- Sized to support the mould housings assembly- Designed to permit mould oscillation along the casting radius- Adjustable stroke, frequency and negative strip time.- Easy access to the mechanism itself- Protected from the cooling chamber environment.- Allowing for fast and precise positioning.

Different Designs

Electro-mechanicalHydraulicAir springMechanical Spring

CVS - CCMSecondary Cooling

-Heat resistant concrete walls- Modular structure- Steel doors and walkways allow maintenanceaccess to the sprayers and to the bow guide.-Visual inspection openings.-Steam extraction fan.-Automatic Control of Spray Water Quantity- Completelly water spray nozzle or air mistdesign- Guiding rollers

CVS - CCMWithdrawal and Straightener

CVS - CCMDummy Bar

- Rigid design

-Safe operation

-Faster restranding of strand

- Quick automatic disconnecting operation.

CVS - CCMLateral Transfer System

Designed to move the billets from theelevated position above the discharge rollertable to the cooling bed area.

The transfer system is composed by abridge beam that spans over the removalarea and translates across it.

CVS - CCMCooling Bed

The bed is composed by two frames having aset of mounted blades: one frame is fixedwhile the other is alternately moved in avertical and horizontal direction by two sets ofhydraulic cylinders.

During its movement, the movable frameadvances the billets along the fixed frame thusallowing an uniform cooling of each bar.

CVSSCRAP BUCKET PRESS

UP TO 60 % INCREASE IN THESCRAP DENSITY IN SCRAP BUCKETTHANKS TO THE HYDRAULIC FORCEUP TO 250 TON LOAD.

CVS - SCRAP BUCKET PRESSWHY TO CHOOSE

- Can be installed on any type scrapbucket

- Lowest Investment Cost

- Easiest Installation

- Consists of a large verticalpressure block that compresses thescrap within the bucket.

- Since it is totally protected, it ispractically maintenance free.

- High speed and fully automateddesign.

CVS - SCRAP BUCKET PRESSFEATURES

- All safety features can beprovided as per EuropeanNorms.

- Rigorously tested prior to thedelivery

- Load up to 250 ton

- Heavy and Rigid construction

- Convenient and SafeOperation

- Giving Flexibility for ScrapPreparation

CVS - SCRAP BUCKET PRESSCVS ADVANTAGES

-Shorter tap-to-tap time

The possibility of a higher scrapdensity allows the power-off timeto be shortened by as much as 1bucket less charge.

-Improved productivity

-Thanks to a faster operation, thepower off time can be reduced byup to 20%.

-It's possible to achieve an overallup to 10 % increase in productivity.

CVS - SCRAP BUCKET PRESSPRESS OPERATION

PRESS OPERATION

PARK POSITION

CVS - SCRAP SHEAR

The design of the CVS press shears is based on the concept with cylindric guides for theshear head ensuring a precise cut between the upper and lower blades.

The shear is build within a robust, twist resistant welded construction allowinginstallation directly onto concrete without anchorage and therefore having low foundationcosts.

The shear is equipped with a hydraulically operated filling box which allows charging ofthe shear during production. This design decreases the charging time and increases theproductivity.

The machined pressing box ensures the precise movement of the compactors as well asfast and stick free pre-compaction of bulky scrap.

The extra long vertical holder guides allow the scrap that has been pre-compacted bythe side-compactor to be pressed against the lowered vertical holder, allowing bales canbe produced as well.

CVS - SCRAP SHEAR

CVS -Scrap preheating Systems

Preheating of scrap by utilizing sensible heat of exhaust gas emitted from an EAF havebeen investigated for many years in many plants.As a result of scrap preheating, notonly the electric power and time required for steelmaking but electrode and refractoryconsumption has decreased.

Condition of temperature on the preheating system:- Inlet temperature of preheater: approx. 8000C – 2000C- Outlet tempearture of preheater: approx. 2500C – 500C- Temperature of preheated scrap: approx. 4000C – 1000C- Temperature at combustion chamber inlet widely varies between 12000C to 3000Caccording to the time and conditions of the steelmaking stages.

Outlet temperatures of the preheating system stays at low temperatures whichindicates that heat absorption by scrap is fully accomplished. Temperature of scrapindicates the difference between upper and lower parts of the charging bucket.

Main Profit:

Preheated scrap average temperature is between 150°C - 200°CThe amount of energy saving is 20 – 30 kwh/ton in practice.

CVS -Scrap preheating Systems

-Easy Solution

-Low Investment Cost

-Better Operation

-Adaptable for Existing Automation

-No dioxin

- Maintenance Friendly

CVS -Outline for CVS Scrap preheating Systems

•Heat energy contained in a gas evacuated from an EAF accounts for 15 to 20 % of thetotal energy used in EAF steel making process and that is 100 – 150 kwh/ton.•CVS scrap pre-heater is a system which utilizes this heat energy to heat scrap in a bucketbefore charged into an EAF and thus contributes towards energy saving.

Gas evacuated from the EAF is led to a combustion chamber through a suction ducttogether with air induced through gap between EAF elbow and sliding sleeve duct to burnCO contained in the gas, a part of this burned gas is introduced in to the bucket placed atthe scrap to heat scrap. After passing the bucket, the gas is returned to the combustionchamber by a preheating fan. This is called Recycle Flow in the system.

When scrap does not contain oil and other combustibles, the gas after preheating my besent to the duct collector. This is called Direct Flow in the system.

For Recycle flow, combustibles contained in the gas after preheating is burned by mixingwith the gas from the EAF. This enables to eliminate an air pollution after dust collector.

CVS -Outline for CVS Scrap preheating Systems

It is important to minimize gas leakage in a preheating line. For this purpose, specialsealing devices are provided between hood pipe and inlet duct, hood and scrap buckettop edge, bucket cylinder and clamp shells.

By use of the adequate sealing devices, air introduced into the scrap pre-heater is verysmall.

By provision of preheating fan, existing fume treatment plant can employ the scrap pre-heater without modification.

As the system is fully automatically operated, this system does not require additionalworker.

EAF operation will not be interrupted even if the preheating system run into a trouble.Recycling method of preheating system can be controlled separately from dustcollector system.

Proper adjustment of the preheating temperature prevents the scrap bucket from beingdeformed.

CVS -Carbon Handling System

Carbon Handling Cost: Less than 30 USD/ton (depending on unit price ofconsumable items)

70 USD/ton saving from operationInvestment Pay-Back Maximum 10-months

CVS -Carbon Handling System

Design FeaturesUp to 5.000 ton/monthStarting CarbonSize: 0-100 mmHumidity: Up to %25End Product:Humidity: Less than 1 %3-8 mm Carbon (10-40 %)0-3 mm Carbon (30-80 %)Dust: Less than 6 %Energy Consumption:Less than 8 kWh/ton CNG Consumption:Less than 30 Nm3/ton C

Design Advantages

Low dustFast Pay-backMinimum InvestmentMaintenance FreeLow operation CostHigher productivitySafe OperationFully-automaticAdaptable for

automatic feeding

CVS - FTPDesign Concept

FTP DESIGN

From EAF Roof Elbow to Stack, CVS provides complete Fume Treatment Plants withengineering, design, manufacturing and installation. Design considers also LF, MHS,canoppy and other dust emitting points by the goal of ZERO DUST EMITION toenvironment. CVS offers economically viable solutions at European standards.


The dedusting system consists of aset of fume collection points and aset of ducting lines (water-cooled orradiant type), which convey thevarious emissions to the bag filteralready under implementation.

CVS designs FTP with the followingaim:•minimum operation andmaintenance costs;•optimal utilization of spaces inside/ outside the meltshop;•automatic operation, “hands-off”type; andtwenty-four hours operation.

CVS designs FTP to collect, suck and treat the primary and secondary emissionsgenerated by the EAF, the primary emission generated by the LF and the emissionemitted by the Material Handling System.


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 andprimary fumes 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.

CVS - FTPTypical Filter Unit

CVS - FTPTypical Canoppy Hood

CVS - FTPTypical Pelletizer

CVS - FTPDesign Focus

CYCLONS

STACK

EAF

COOLER

SETTLINGCHAMBER

W.C. DUCT

CANOPY HOOD

FAN FANBAG-FILTER

AUX

LF

ReliabilityReduced maintenance requirementsReduced operating cost (electrical energy, compressed air)Low residual dust content at stackLow noise emission technologyEnvironment Friendly

CVS - FTPTypical Drawing

CVS -Converter Off-Gas System

WE FOLLOW LAST TECHNOLOGIESWHEN WE MANUFACTURE OFF GASSYSTEMS

CVS -Converter Off-Gas System

CVS - Material Handling System

CVS - MHSDesign Concept

The plant is divided into three main parts:

a) Equipment for Ferro-alloys and additives storage from receiving hoppers to thebins battery

b) Equipment for Ferro-alloys and additives extraction, dosing and weighing,transport and charging into furnace, ladle in tapping position and L.F.

c) Equipment for Carbon and lime extraction, dosing and weighing, transport andcharging into scrap buckets.

CVS - DRI Continuous Feeding System


It is possible to charge HBI up to 30% without continuous feeding, and up to 100%using top feeding.

Slag control, feeding rate and power input are the key factors in continuous chargingprocedures.


Continuous feeding of HBI is typically performed to:

• To eliminate one or more buckets from the charge,thereby reducing heat losses and power off time• Allow high rates of HBI use.• Boost productivity and reduce heat losses bycombining melting and refining.

Physical requirements forcontinuous feeding of HBI andDRI:

• HBI must be present as singlebriquettes or pieces to preventjamming on conveyor belts andtransfers,

• A maximum briquettedimension that is less than 50%of the minimum hopper opening,

• Low abrasion index to preventexcessive dusting and yieldloss.

CVS - Slag Processing System

Primary and secondary jaw crushers are designed tocrush all kinds of stone regardless the hardness andabrasives.

They are the most advanced jaw crushers availablewith hydraulic settings, central lubrication, highperformance, efficiency and capacities.

Slag has been recycled and effectively used as a base coarse material (road bedmaterial). Now, it is also possible to use soil-improvement material (for hardening of softground).

CVS - Slag Processing System

-Removal of slag residue from refined iron 0 - 8 mm

-Metal recovery from slag and waste incineration ash

-Production of concentrates with a high metal content in first step

-Hydraulic sizing for the removal of fine components at cut - points 1 - 8 mm

-Removal of filler material from the fine fraction prior to the use of next step separators

-Reduction of crusher feed by pre-separation off non-metallic slags

-Selective comminution of metal-slagcomposites, special types of crusher areavailable

CVS - Water Treatment PlantTypical Equipment

CVS - Water Treatment PlantTypical Equipment

CVS - Water Treatment PlantDesign Scope

Scope of services:

Utilities and storage systems

Water supply and treatment plants

Scale water and muddy water treatmentplants

Project planning, feasibility studies andproject management

Monitoring activities for installation aswell as commissioning and plant operation

Engineering and project managementfor piping systems

CVS - Water Treatment PlantDesign Concept

In the modern metallurgical industry, efficient water management is not only ameans to an end, but a guarantee for economic and ecological process flows.

Perfect integration into the entire system is vital to ensure competitiveness in thefuture. The implementation is always adapted to local legal requirements,environmental protection conditions and customer standards.

Modern water management is mainly affected by three factors:

quality of the make-up water,

climatic conditions

legal requirements.

These are partially determined by varying regional conditions. Thanks to our manyyears of experience in the various regions of the world and our comprehensiveprocess knowledge in plant construction, we’re able to professionally incorporatethese localized, varying factors into the plant design.

CVS - Water Treatment PlantDesign Advantageous

Main benefits:

All systems are optimally integrated into theproduction plants

Single-source responsibility is ensured forthe entire metallurgical process

Compliance with all environmentrelevantrequirements is guaranteed

A total solution provider as well as asupplier of individual products andcomponents meets all of your requirements

CVS -Piping and Erection for Oxygen Plant

CVS -Piping and Erection for Oxygen Plant

CVS - AUTOMATIONEAF – Arc Regulation System

Arc Regulation system (ARS) forEAF applications is the lateststage of development whichusing PC based Windows XPoperating system.

Using a special algorithmfollowing benefits can beoffered to customer;- Fast adjustment of arc length,- Fast response and fast andstable control,- Minimizing of powerconsumption,- Minimizing of flicker effectsdue to regulation quality,- Minimizing of electrode andrefractory consumption.

CVS - AUTOMATIONEAF – Voltage & Current MeasuringSystem

Actual voltage and current offurnace are read by specialanalog/digital converter cardinstalled on the PC.

Generally the current of primaryside of the transformer isconverted in order to make thefurnace main PLC panel readthese current values.

The conversion is made bycurrent transformer oftransformer and the matchingtransformer (generally suppliedby transformer manufacturer).

The outputs of the currenttransducer in the furnace mainPLC panel are inputs for A/Dconverter card on PC.

CVS - AUTOMATIONCCM – CASTING EQUIPMENTS

CVS - AUTOMATIONCCM – COOLING BED

CVS - AUTOMATIONFTP – COMBUSTION CHAMBER

CVS - AUTOMATIONFTP – CYCLONE & FILTER


ROLLING MILL DESIGN

From Bar mill to Section Mill, From Chimney to complete Reheating Furnaces, fromRoll Stands and water quenching system to complete Rolling Mill Train, fromCooling Bed Area to Handling Area, from Flying Shears to Cold Shears, FullAutomation System and from Engineering Services to Turn-Key Plants, CVS offerseconomically viable solutions at European standards.

CVS - ROLLING MILLRolling Mill Turnkey Solution

• All mechanical equipmentincorporates the latest known andproven technology.

• All mill stands are housinglessseries, which are known worldwidefor their rigidity and ease ofmaintenance.

• The stands can be used forproducing all grades of steel up toand including stainless high speedand high alloy steel.

• Special "robots" are used for quickroll changing thus reducing therequirement for costly spares andstand by equipment.

CVS - ROLLING MILLRolling Mill Turnkey Solution

• All the rolling mill stands areindividually driven by motors

• Inter-stands tension of the barcan be controlled to acceptablelimit.

• Improved quality of the finishedproduct

• Reduced risk of scrap or cobbledbar.

• Flying shear is provided toremove the oversize head of thebar as it progresses down therolling line.

• Maintenance friendly design

CVS - ROLLING MILLRe-heating Furnace

- up to 100 tph nominal capacity

- furnaces complete with charging table and discharge roller table.

- Walking heart type, pusher type or walking beam type.

- Design of special emphasis on fuel saving and operational efficiency.

- Recuperation, provided to further increase the overall fuel efficiency.

- The discharge machine, called kick-off, controlled from the main pulpit.

- Minimized the manpower so that only furnace pulpit operator will beresponsible for both furnace operation and billet charging.

CVS - ROLLING MILLTypical Loopers

CVS - ROLLING MILLTypical Shears

CVS - ROLLING MILLTypical Binding Machines

CVS - ROLLING MILLRolling Mill Cooling Bed and Packing

CVS -Designing General Layout

The plant is designed according to the latest technology in the field of steel plantmachinery and equipment.

The layout takes full advantage of the rationality of material handling in the plantin order to obtain the following results:

•Minimum amount of areas occupied•Optimization of personnel required•Optimization of production times and costs.•Best scrap handling•Future Extension consideration of plant

The layout of the meltshop and the location of Auxiliary Plants have beencarefully analyzed for best logistics inside the plant like raw materials, semi-products and waste material.

CVS -Designing General Layout

The choice of the various systems making up the plant is strictly related to theachievement of the following high-priority objectives, namely:

•Limited investment costs•High quality products•High productivity•Maximum simplicity of operation•Operation reliability•Maximum flexibility to meet various market demands.

CVS -Optimised Process

We lay the foundation for optimized processes with proven, leading productsworldwide, including mechanical and technological engineering for metal productionand rolling as well as process control engineering, drive engineering and power supply.

Integrated online and offline process models reflect decades of practical experienceand help to ensure reliable, reproducible quality.

Our process engineering expertise fuses these products into complete plant solutionsthat also accommodate the upstream and downstream processes.

These solutions are the basis for optimal resource use, minimized waiting times andreduced maintenance and spare parts costs, as well as wide flexibility with respect toraw materials and the resulting products.

A further factor for competitive production is the quality of information processing.Production data must be consolidated and compared with planning data to ensureoptimal production flow.

CVS -Training and Technology Transfer

Whenever CVS recieves an order for steelmaking equipment, engineering services andknow-how transfer are mutually agreed upon between both parties.

Thanks to our experience, there is no question that we know that this is fundamentalbasis for succesful production equipment.

The second step of know-how transfer is an off-site training of customer’s engineers,technicians and skilled workers.

The main target of training on the customer’s site is to familiarise their personel withhands-on operation ofthe supplied machines and equipment.

The operators and maintenance personel are trained step by step to prepare them forsuccessful operation of the equipment.

CVS -Typical Learning Curve for Meltshop

0,25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 184 198 428 548 586 657 670 733 730 762 619 540 674 591 729 698 751 709 796

341,6 17961,1 39941,5 51685,9 54609,7 62349,2 63248,3 67077,4 67.623 71.479 55.998 63082,4 82320,1 69460,9 89.970 86.726 93.902 88.698 98.376

0

100

200

300

400

500

600

700

800

900

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18Months

Hea

ts /

Mon

th

0

10000

20000

30000

40000

50000

60000

70000

80000

90000

100000

Tons

/ M

onth

(liq

uid)

Heats, - Production, tons liquid

Nominal / month83.333 ton (120 to)

90 t/heat 120 t/heatX

Typicalexpectedvalues:

80%production rateafter 8 months

100%production rateafter 10 months

CVS -Erection and Site Management

Steel Structure:

Project management of engineering companies and fabrication shops

Structural design engineering including static and dynamic calculations

Shop drawings

Preparation of tender documents and evaluation of bids

Quantity survey for invoicing purposes

Fabrication of steel structure

Supervision of fabrication

Design studies for economic solutions


For erection engineering, site management and site monitoring, our professional handlingof the site ensures the quality of the plant and guarantees adherence to both the budgetand the schedule.

In addition, our experts have experience in dealing and working together with people fromdifferent cultural groups. With their social sensitivity, motivation and leadership ability,they ensure a perfectly functioning site.

On-site health and safety

Our staff is well trained with regard to health and safety issues. Compliance withinternational, local, customer and company regulations is mandatory, and is assessed ona regular basis


Erection engineering & site management

Cost estimation for site management andexecution of erection

Preparation of time schedules for greenfieldand brownfield projects

Preparation of site organization, siteregulations and safety rules

Preparation of tender documents for theexecution of erection

Final accounting of subcontractors

Change management

Enforcing safety rules and site regulations

Follow-up of progress and budget


Assuring quality requirements

Providing facilities & accommodation

Regular coordination with customer

Supervision of erection:

Checking the completeness of suppliestogether with the erection contractorsInstructions for storage, erection,surveying and testing

Securing the timely, proper andprofessional execution of erection


Main benefits:

Experienced engineers, site managers and supervisors with a well-founded and widerange of state-of-the-art experience, as well as cultural awareness are available.

Selection of erection contractors is optimized in accordance with the scope of work,local conditions and their experience.

Single point coordination of the entire site activities including time scheduling for anoptimized erection time, and budget planning, ensures the lowest possible costs andbest possible quality.

CVS -Turn-key Solution

CVS -TOSCELIK PROJECT

CVS -NURSAN EAF PROJECT

NURSAN holding is one of the leadercompany in Turkey, especially in Southpart of Turkey. Rolling mill plant startedproduction in 1984.

After his fast grow, it is decided tomake investment for billet production.New meltshop started production in2003.

The same fast grow has been seenthanks to well oriented, expert anddynamic team.

In 2008, they decided to increasefurnace capacity and signed contractwith CVS for high efficiency,environmet-friendly, maintenance freespecial furnace design.

CVS -NURSAN EAF PROJECT

Furnace has reached 35 heats/dayaverage production thanks to co-operative work between CVS andNURSAN technical team duringdesign, assembly and start-upperiod.

CVS -TOSCELIK PROJECT

TOSCELIK project is our one of turn key project in Turkey.

TOSYALI holding was one of the leader company in Turkey especially in pipeproduction. They decided to make new meltshop and rolling mill investment forlong production and slab production. They awarded CVS for comple turnkeysolution.

Turnkey Project Covers following Units:

• Steel Structure• SVC Unit• 155 ton AC Arc Furnace• Ladle Furnace• 6 strand CCM• 2 Strand Slab Caster• Hot strip mill• Fume Treatment Plant• Water Treatment Plant• Oxygen Plant• Other steel plant facilities

DESIGN & ENGINEERINGWE INVEST IN RESEARCH AND DEVELOPMENT FORPERPETUAL IMPROVEMENT IN INNOVATION

DESIGN & ENGINEERING

We believe it all starts at thedrawing table


We put our experience andknow-how in steel industrybehind our products and

services


Our people are the mostimportant assets at CVS

CVS -QUALITY MANAGEMENT

QUALITY IS NOT ONLY OUR

POLICY BUT OUR

PHILOSOPHY

CVS -GENERAL POLICY

WE FEEL OURSELVES IN THE CORE OF STEEL

WE BELIEVE OUR KNOWLEDGE

REFERENCES

KURUM DEMIR ALBANIAVAI POMINI AUSTRIAARCELORMITTAL CARINOX BELGIUMARCELORMITTAL INDUSTEEL BELGIUMDUFERCO BELGIUMELLWOOD BELGIUMBH STEEL BOSNIA HERZEGOVINASTOMANA BULGARIAARCELORMITTAL DUNKERQUE FRANCEBK SERVICE GERMANYSALZGITTER GERMANYSMS DEMAG GERMANYVAI FUCHS GERMANYHALYVOURGIA GREECEHALYVOURGIKI GREECESIDENOR GREECESOVEL GREECEABS ITALYALSTOM POWER ITALYARCEMI ITALYDANIELI ITALY

EUROPE

REFERENCES

FERRIERE NORD ITALYSMS MEER ITALYTHYSSEN KRUPP ITALYARCELORMITTAL LUXEMBOURGARCELORMITTAL SKOPJE MACEDONIAMAKSTIL MACEDONIAGMZ RUSSIAMMK RUSSIAREVYAKINO RUSSIACONCAST SWITZERLANDMTAG MARTI SWITZERLANDCORUS THE NETHERLANDSEMSS UKRAINESIEMENS VAI UNITED KINGDOMTHAMESTEEL UNITED KINGDOM

EUROPE

REFERENCES

IRAN ALLOY STEEL IRANKHAZAR BILLET IRANKHORASAN STEEL IRANHOD METAL ISRAELYEHUDA STEEL ISRAELCOJSCO JORDANJORDAN IRON JORDANUNITED IRON JORDANSHARQ SOHAR OMANAL HADDAD PALESTINECOPSCO PALESTINEQATAR STEEL QATARAL RAJHI SAUDI ARABIAAL TUWAIRQI SAUDI ARABIAAL WAHABI SYRIA

MIDDLE EAST

REFERENCES

AL EZZ GROUP EGYPTARCO STEEL EGYPTEGYPTIAN IRON & STEEL EGYPTSUEZ STEEL EGYPT .TAYBEH STEEL EGYPTSONASID MOROCCO

NORTH AFRICA

REFERENCES

INDUSTRIAS NACIONALES DOMINICAN REPUBLICCHARTER STEEL USAHOGANAS USATIMKEN USA

NORTH AMERICA

REFERENCES

ASIL CELIK TURKEYAKDEMIR TURKEYCER CELIK TURKEYCOLAKOGLU TURKEYCUKUROVA TURKEYDEMIRSAN TURKEYDILER TURKEYEKINCILER TURKEYEGE DEMIR CELIK TURKEYERDEMIR TURKEYHASCELIK TURKEYICDAS TURKEYISDEMIR TURKEYIZMIR DEMIR CELIK TURKEYKAPTAN TURKEYKARDEMIR TURKEYKROMAN TURKEYKUMAS TURKEYNURSAN TURKEYSIVAS DEMIR CELIK TURKEYTOSYALI HOLDING TURKEYYESILYURT TURKEYYUCEL BORU TURKEY

TURKEY


Thank You For Your Patiencewww.cvs.com.tr

http://www.cvs.com.tr

cvs general ion 09

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