eaf basics ppt

8/12/2019 EAF Basics Ppt

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Industrial Accessories Company4800 Lamar Ave

Mission, Kansas 66202

Electric Arc Furnace

TechnologiesCorporate

Background

PP003


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Regulatory RequirementsCoke Oven-Pushing Emissions New Mact Standards for Opacity (20% opacity during push).

Will require more efficient capture.

May require capture of "travel" emissions.

Blast Furnaces

May require retrofit from ESP &/or Venturi Scrubber to Baghouse

Primarily FF, however there are 2 VS installations.

PM control - 0.009 gr/dscfOpacity - 20% for existing plants; 15% for new plants.

Basic Oxygen Furnace (BOF) All US "Open or Closed Hood" designs have either an ESP or VS.

Primary Control BOPF w/Closed Hood - 0.024 gr/dscf

BOPF w/Open Hood - 0.019 gr/dscf

Secondary Control 0.01 gr/dscf for existing plants

0.0052 gr/dsf for new plants

Electric Arc Furnace (EAF) EAF Control Device: Lead Emissions of 0.0002 grains/DSF

EAF Control Device: Opacity of 3%

Melt Shop Building Roof Ventilators: Opacity of 6%EU developing new standards for EAF emissions for following:

* arsenic; cadmium; nickel; and Polyaromatic hydrocarbons (PAHs)

* Once standards get adopted, US market will also be affected.

Sinter Plants

Windbox Exhaust 0.3 lbs per ton of product sinter (old & new plants)

Discharge End 0.02 gr/dscf - existing plant; 0.01 gr/dscf - new plant

20% opacity for secondary emissions - existing plant

10% opacity for secondary emissions - new plant

Cooler stacks 0.03 gr/dscf - existing plant; 0.01 gr/dscf - new plant.

General Bag leak detection systems

Opacity Monitoring

Continuous parameter monitoring system

Record keeping

For Steel installations, the general accepted limit is 0.0052 gr/dscf


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EAF Process Design

Bleed-In-Air Damper

Opposed Blade Dam per

Break Flange/Retractable Duct

Water Cooled/Refr actory Duct

Pressure Sensor

Fce Elbow

W/C or Refractory To Baghouse / ID Fans

(Suction or Pressur e Design)

Water Cooled/Refr actory Duct


Combustion

ChamberQuench

Tow er

Canopy Hood

Louver Damper


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EAF & Ladle FurnaceCanopy Hood

Louver Control Damper

Combustion Chamber


Break Flange /

Retractable Duct

Bleed in Air Damper

Damper

Hot Quenching

Ladle Furnac e

Break Flange /

Retractable Duct


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DEC / 4TH Hole Exhaust


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Water Cooled Duct With W/C Damper


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Side Draft Hood

Enclosure Box DesignE l e c t r o d e s

E L E C T R O D E C l a m p h o ld e r

F u r n a c e M a s t h o ld i n g t h e e le c t r o d e s

B r a c k e t s

F u r n a c e M a s t h o ld i n g t h e e le c t r od e s

H o o d w i t h t o p p l a te a n d o p e n b o t t om

A t th i s e n d , th e h o o d w i l l h a v e l o u v e r s , w h i c h c a n b e m a n u a l l y a d j u s t e d . T h i s w i ll a l l o w d i l u t i o n a ir to

e n t e r a n d t o d i v e r t th e f u m e s c o m in g o u t o f t h e e l e c tr o d e h o l e s .

E l e c t r o d e H o le O p e n i n g s ( 3 m i n . c l e a r a n c e f o r t h e e l e c tr o d e )

T h e a b o v e h o o d d e s i g n c a n b e i n s t a ll e d b e t w e e n t h e m a s t a n d t o c o ll e c t t h e e m i s s io n s t h a t e s c a p e b e t w e e nt h e a n n u l a r s p a c e b e t w e e n t h e e l e c t r o d e a n d t h e f u r n a c e r o o f h o l e s f o r t h e e l e c tr o d e s .

I n u s i n g t h i s d e s i g n , t h e fo l l o w i n g m u s t b e r e v ie w e d c a r e f u l l y :

1 . T h e m a s t h o l d i n g t h e e le c t ro d e s c a n o n l y b e lo w e r e d t o a p o i n t a b o v e t h e h o o d . T h i s w i l l l im i t t h e

m a s t m o v e m e n t . I n m o s t E A F s th i s i s a c c e p t a b l e.2 . T h e h o o d w i ll h a v e t o b e s tr e s s r e li e v e d a n d c o n s tr u c t e d o f S S 3 1 7 - L . I n o p e r a ti o n , th e h o o d w i ll

t a k e a n i n i ti a l w a r p a n d t h e n w i l l s ta b i l i z e .3 . T h e d u c t ta k e - o f f f ro m t h e h o o d w i ll h a v e a b r e a k f la n g e t o a c c o m m o d a t e th e r o o f s w i n g .


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Side Draft Hood

Finger Hood Design

To Baghous e

Pivot Point for Roof

Bre ak Flange

Fur nace Roof Mast

Slag Door w ith Vent

Pour Spout

EXHAUST L OCATION

Ar ou nd Elect rod es

Slag Door

Tap Spout is plugged for the Melt Cycle

Des ign allow s fo r coolin g Air at Bre akflange . Exhaust t o Baghous e at 250 F.


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Canopy Hood DesignDes ign 1830,000 ACFM

18'-0" Dia Duct

Louver Dam per Louver Dam per

9'-0" X 9'-0" 9'-0" X 9'-0"

Tapping Melting Slagging


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Canopy Hood DesignDesig n 2

830,000 ACFM

18'-0" Dia Duct

Louver Dam per

9'-0" X 9'-0"

Tapping Melting Slagging


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Canopy Hood DesignRELADLING OPERATION

CANOPY HOOD DESIGN

Low Profile Canopy Hood w/Two Discharge Ducts (each w/inner duct)

Side Discharge

B

HLP

A

X

Y

D

E C

No te : Ho od i s l oc ate d a bo ve Cr an e

Locate Hood as close as possible to the top of the ladle

Dimensions not provided, are assumed

Y 5.5 m 7 m

X 3 m 4.5 m

C 2 m 2.6 m

D 4 m 4 m

E 1.1 m 1.5 m

A 6.6 m 8.1 m

B 8 m 10.5 m

HLP 3 m 4 m

HTC 5.5 m 6.7 m

Low Profile Hood (acfm) 142,000 228,868

Low Profile Hood (am3/hr) 241,258 388,847

Tradition al Hood (acfm) 170,400 274,641

Traditional Canopy Design

Top Discharge

HTC

B

A

X

Y

C


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IAC M PulseIAC "M" PULSE MODEL

Condition Flow Temp (F) IAC M-PULSE Baghouse

EAF 217,000 acfm 250 6 X 234TB-BHWT-360:S6

12 Penthouse w /Monorail

2

~ 6'-0"

Pneumatically Operated

Roof Door Outlet Poppet Dampers 14'-0"

One/Compt.

3'-6" Compt Outlet

23'-6"

9'-0"

Inlet Damper

Manual/Butterfly

Hd

2'-6" 60 Deg Side Angle

12"x12"

W To Suit

Grade

Baghouse Width

ELEVATION - TYPICAL SECTION THRU COMPARTMENT

Note: 1. Design of Inlet/Out let Plenum is prel iminary

2. The Header will be 12" Diameter (min).

3. Puls e Valves 2 1/2" min.

INLET PLENUM

(Tapered)

IP

h

IPw

OUTLET PLENUM

(TAPERED)


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Side ElevationIAC " M" PULSE MODEL

Condi tion Flow Temp (F) IAC M-PULSE Baghouse


~ 6'-0"

14'-0"

3'-6"

3'-0"

OPh

23'-6"

IPh

A

CIh

6"

Hd

12" x 12"

Compt. Length

10'-0" Baghous e Length

Grade

CIw

Dirty Air Hous ing

Compt. Outlet

Compt. Inlet CIw


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Velocity ProfileIAC "M" PULSE MODEL

Com pt length "L" Poppet Dam per

EAF Plenum Width

Flow: acfm 217,000

# of Compts. 6

Flow to One Compt. acfm 36,167

W ft 15.7

L ft 15.0

Inlet Damper-Height ft 3.5 Outlet Plenum Height

Inlet Damper-Width ft 6.89

Compt. Outlet - Height ft 2.5

Compt. Outlet - Width ft 8.0

Poppet Damper Size in. 48

Inlet/Outlet Plenum Width ft 10.5

Inlet/Outlet Plenum Height ft 5.9

VELOCITY PROFILE:

Inlet Plenum: fpm 3500 Inlet Plenum Height

A Across Inlet Damper fpm 1500B 40% Flow to Hopper fpm 386

C 60% Flow to Casing fpm 579

D In to Upper Casing fpm 132

E From Hopper fpm 73

F Exit from Compt fpm 1800

G Across Poppet fpm 2878

H Outlet Plenum: fpm 3500

Inlet Damper

2'-6"

Compt w idth "W"

INLET PL ENUM

F

D

C

B

E

OUTLET PL ENUM H

G

A


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Tube-sheet DesignIAC "M" PULSE MODEL

W

14" 8"

8"

11" (typ )

8"

Row s

L

Inlet Flow

Bags /Blow Pipe 2'-6"

NOTE: Tube sheet d imens ions are approximate . Inte rnal s ti f fne rs fo r common wal l cons t ruc ti on may ex tend w id th.

PROJECT EAF

BAGS/COMPT 360

# ROWS 20

BAGS/BLOWPIPE 18

W (FT) 15.67

L (FT) 15.00


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Plan View - One Door/HeaderIAC "M" PULSE MODEL

Condition Flow F IAC M-PULSE Baghouse


Inlet Outlet

Baghous e Width (Bw)

Baghouse Length (Bl)

EAF

# Compartments 6

Flow: acfm 217,000

Compartment Width ft 15.67

Compartment Length ft 15.00

Baghouse Width ft 41.8

Baghouse Length ft 45.0


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M - Pulse Baghouse

Header Design Arrangement

90 Degree; Thr eaded, Double Diaphram Valve

3" Valve (Typical)

Header

Typ. 3" Blow-Pipe

Roof Top Door (6" High)

Outlet

8"

Typ . 3" Blow-Pipe (3 1/4" OD) 2" Over lap

Nozzle 2" 6"

(1 1/4" Sch 40)

3/16" Plate Tube s heet

Tube Sheet Hole: 6 1/4"

Bag & Cage:

6" Diameter

Cage: 5 3/4" Dia.

Inner Strike Plate

Bag to w all clearance is 3" (min)

Inlet Flow


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M - Pulse Baghouse90 Degree Threaded Double Diaphragm Valve


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M - Pulse BaghouseFull Immersion Design Header

Tank has integrated diaphragm valvescontrolled by remote solenoid pilots


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Heat Exchanger

1.

Forced Cooling Fan, which blows cooling air in to the inside of the coolingtubes/pipes and the process gas is on the outside of the tube. The tubes/pipes are

located horizontally.

2. The hot process exhaust gases are vented to the Air to Air Heat Exchanger where they

pass through vertical parallel tubes. Cooling is accomplished by forced convectioninduced by cross-flow fans moving ambient air over the outside of the tubes.


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Evaporative Cooling

Hot Gas Inlet Flow

Platform for access to nozzles

Acces s Lad de r

Evaporative Cooler

Cooled Gas Outlet Flow

To suit

Grade


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Lance / Nozzle DesignLance Assembly is constructed in 316 SS

8" 150lb. Flange s tandard (1" / 25.4 mm thick)

13.5" OD (342.9 m m)

11.75" 298.5 mm ) Diamet er bolt hole cente r

7.5" 190.5 mm Distance to suit Cooler Size

Liquid Inlet

1" NPT or BSPT

8.23" (209.1 m m)

2 1/2" sch 40 p ipe 2.75" (69.9 mm Hex

4" 2.875" OD

Nozzle Tip has 8 holes (fr ee pass age)

Air Inle t

1" NPT or BSPT

Nozzle Tip ConfigurationSpray Velocity designed in the range of 80 to 125 ft/sec (24.5 to 38.2 m/s)

0.188" (4.7 m m) to 0.393" (9.9 mm )

8 Holes

2.38" (60.3 mm ) to 2.75" (69.9 mm )


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Nozzle Dispersion

48"/1.22M

v y

Spr ay Velocity

"z"

A d iam et er

B Diame te r

NOZZLE PERFORMANCE REQUIREMENT

US UNITS METRIC UNITS

Atomizing Air Pressure: 20 / 40 / 60 / 70 / 80 psi 1.38 / 2.76 / 4.14 / 4.83 / 5.52 bar

Liquid Pressure: 13.9 to 95.5 psi 0.96 to 6.59 bar

Liquid Capacity: 0.5 to 30 gpm 1.89 to 113.56 l/min

NOZZLE DISPERSION ANALYSIS:

1 Spray Dimensions (y; and z)

2 Spray Velocity (v)

3 Spray Cloud Diamete r (A & B)


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Radiant Cooling

Radiant Tubes

(Height to suit)

Expans ion Joint

Screw Conveyor Rotary Valve

Grade


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Double Dump Valve Technology

Pneumatic Conveying


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Standard Products Pneumatic Conveying

Mechanical Conveying

Air Supply Equipment Valves/Flow Control

Bulk Storage

Baghouses


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Services Engineering Evaluations

System Design/Specification

Field Evaluation

Troubleshooting

Installation & Start-up

Maintenance

Scheduled/Preventive/Emergency

Bag Change-outs

Equipment Upgrades/Optimization

Turnkey Projects

Training - Operation/Maintenance


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IAC Key ReferencesRepresentative Reverse Air References Iron & Steel Industry:

1. Krupp Industrie GER 1,765,000 ACFM EAF

2. Hadeed Ltd. SAU 1,059,000 ACFM EAF

3. Gret Lakes Steel USA 1,231,000 ACFM EAF

4. Ferrowohlen SWI 765,000 ACFM EAF

5. Crucible Steel USA 865,000 ACFM EAF6. CF&I USA 540,000 ACFM EAF

7. Cascade Steel USA 486,000 ACFM EAF

8. Bethlehem Steel USA 874,000 ACFM EAF

9. Nucor, Kankakee USA 450,000 ACFM EAF

10. Kaiser Steel USA 600,000 ACFM Reladling

11. Wheeling Pittsburgh USA 180,000 ACFM Reladling

Representative References Boilers and Dry FGD:

1. C&H Combustiion USA 465,000 ACFM FBC/Incineration

2. Ormet Aluminium USA Pot Line Dry Scrubber

3. Reynolds Metal USA 141,000 ACFM Anode Bake Fce

4. Intalco Aluminium USA 168,000 ACFM Anode Bake Fce

5. ICM, Nevada, IA USA 165,000 ACFM Coal Fired Boiler6. ICM, Goldfield, IA USA 165,000 ACFM Coal Fired Boiler

7. Cemex, Fairborn, OH USA 65,000 ACFM Alkali By-Pass


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Contact Information

Corporate Address: 4800 Lamar Avenue

Mission, Kansas 66202

Corp Tel: (913) 384.5511 E-Mail: [email protected]

Sales Tel: (800) 334.7431

Corp Fax: (913) 384.6577

Knoxville Contact: Pramodh Nijhawan

318 Saint Andrews Drive

Knoxville, TN. 37922

Tel: (865) 675-7867 E-Mail: [email protected]

Fax:(865) 675-7582

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