pollution control solutions prowess-2k16-1-1

POLLUTION CONTROL SOLUTIONS

BY

PROWESS INTERNATIONAL (P) LTD.

POLLUTION CONTROL SOLUTIONS BY PROWESS

Primary & Secondary Fume Extraction System for EAF/ LRF/EOF/AOD

Secondary extraction through Roof canopy

De-dusting Systems for Raw Material Handling System, Stock House, Blast Furnace Cast House, Submerged Arc Furnace Cast House, Lime Plants etc.

Various components of Gas Cleaning System of BOF

Gas cooling through Gas Cooling Tower with High temperature water quenching or Forced Draft Coolers or Natural Hair Pin Coolers

Bag House : Pulse Jet Type or Reverse Air Bag House (RABH)

VVVF/ Soft starter start up of ID Fan

Complete Auto Operation through PLC with optimized Power consumption

Pneumatically operated feedback controlled dampers

Dust handling systems (Pneumatic Conveying & Conveying through Drag Chain Conveyors)

MAJOR INSTALLATIONS OF POLLUTION CONTROL SOLUTIONS BY PROWESS

Sl. No. Major Installations Year

1. Primary Fume Extraction System for 1x60T EAF of Jai Balaji Group, Durgapur

2008

2. Revamp of Primary Fume Extraction System of 1x50T EAF of Sunflag Steel, Bhandara Road, Nagpur

2008

3. Revamp of Primary Fume Extraction System of 1x100T EAF of Jindal Power & Steel Ltd., Raigarh

2009

4. Primary & Secondary Fume Extraction System for 2x30T EAF + 1x30T LRF for Geco Steel, Syria

2010

5. Primary Fume Extraction System for 1x30T EAF of Shyam Steels , Durgapur

2011

6. Lance Trolley, Movable Tubular Hood with Car & Water-cooled Tubular Ducts for 1x60T AOD of Salem Steel (SAIL)

2012

7. Primary & Secondary Fume Extraction System for 2x100T EAF + 4x100T LRF for Monnet Ispat & Energy Ltd., Raigarh

2013

8. Primary & Secondary Fume Extraction System for 1x30T EAF + 1x30T LRF for Muscat Steel Melting Co. LLC. , Muscat, Oman

2014

9. Primary & Secondary Fume Extraction System for 1x35T EAF + 1x35T LRF for Arora Iron Steel Rolling Mills Ltd., Ludhiana

2015

10. Gas Cleaning System for 1x35T VD for Arora Iron Steel Rolling Mills Ltd., Ludhiana

2015

11. Primary & Secondary Fume Extraction System for 1x45T EAF + 1x45T LRF for Sona Alloys Pvt. Ltd. , Lonand (Near Pune)

Commissioning due.

FUME EXTRACTION SYSTEMELECTRIC ARC FURNACE & LADLE FURNACE

AMOUNT OF DUST GENERATED : 10-20 Kg/T OF CHARGED WEIGHT

MECHANISM OF EAF/LF DUST FORMATION

ENTRAINMENT OF PARTICLES

VOLATILIZATION OF VOLATILE MATERIALS

CO (CARBON MONOXIDE) BUBBLE BURSTING


MECHANISM OF CO, NOX & VOC FORMATION

OXYGEN LANCING IN THE MELT PROCESS REACTSWITH THE CARBON OF THE CHARGE-MIX ANDPRODUCES HUGE AMOUNT OF CO&CO2

NOX IS FORMED WHEN NITORGEN PASSES THROUGH THE ARC OF THE ELECTRODES

VOC FORMS DURING INITIAL STAGE OF MELTING WHEN ORGANIC COMPOUNDS AVAILABLE IN CHARGE-MIX BURNS OFF

CO FORMATION

NOX FORMATION

VOC FORMATION


EMISSIONS FROM ELECTRIC ARC FURNACE

PRIMARY EMISSIONS

EMISSIONS PRODUCED DURING MELTING& REFINING

OPERATIONS OF ELECTRIC ARC FURNACE

SECONDARY EMISSIONS

EMISSIONS PRODUCED DURING CHARGING, DESLAGGING & TAPPING

OPERATIONS OF ELECTRIC ARC FURNACE


TYPICAL FLOW DIAGRAM OF FUME EXTRACTION SYSTEM FOR EAF , LRF & MHS


FUME EXTRACTION SYSTEM : 2X100T + 4x100T LRF EAF AT MONNET ISPAT, RAIGARH

TECHNICAL PARAMETERSTECHNICAL PARAMETER : FUME EXTRACTION SYSTEM : 2x100 EAF + 4x100T LRF

Volume of Fumes 22,00,000 Am3/Hr at 1160C at each Bag-house Inlet Fixed Elbow Duct to Combustion Chamber Tubular; 3800 mm Dia. x 12.5m LCombustion Chamber Tubular; 5m H x 7m W x 12m LWater-cooled Duct up to Forced Draught cooler GCT/HTQ Tubular; 4000mm Dia. x 22m LAir cooled Duct [Secondary Canopy to Secondary Junction ] ID 4800mmAir cooled Duct [4x100T LF to Sec. Duct ] ID 900mm Air cooled Duct [Sec. Jn. to Bag-house ] ID 6100mm Air cooled Duct [Bag-house to ID Fan] ID 6400mm Temp. at inlet of Gas Cooling Tower 800 - 1000 0CTemp. at Outlet of GCT / HTQ 250 - 280 0CFume Temp. at ID Fan Inlet 116 0CCommon Stack (for 2x100T EAFs + 4x100T LRFs) Dia. - 10000mm (at Top) (for 2x22,00,000Am3/hr flow)

Gas Cooling Tower / High Temp Quenching Tower Mist Spray on hot fumes dynamically controlled through

PLC & Lances

Bag House

2 Nos. (Each of Capacity 22,00,000 Am3/hr ) Pulse Jet Cleaning – Off Line Non-Woven Type Polyester, PTFE Treated A to C Ratio (Net) : 1.27 m3/m2/minute Pr. drop across BH : 150 mm WC Clean Gas dust content : 40mgm/Nm3

Booster Fan for LRF Fumes

4 Nos. ( 1 No. for each 100T LRF) 1,00,000 Am3/hr. at 120 0C ; Static Pr. : 300mmWC 110 KW @ 990rpm; 415V

ID Fan for Bag House

5 Nos. (2 Nos. running simultaneously for each EAF (EAF-1 & EAF-2) +1 No. Common Stand-by)

11,00,000 Am3/hr. at 120 0C ;Static Pr. : 380mmWC; 1600 KW @ 990rpm; 6.6 KV; with VVVF Drive


GENERAL LAYOUT

BIGGEST FUME EXTRACTION SYSTEM FOR ANY EAF IN INDIA


FIXED TUBULAR DUCT FOR PRIMARY FUMES

PLAIN DUCTS FOR SECONDARY FUMES COLLECTED THROUGH ROOF CANOPY

COMMON STACK (10M DIA AT EXIT- BIGGEST

FOR ANY EAF IN INDIA)


GAS COOLING TOWER (GCT) OR HIGH TEMPERATURE QUENCHING (HTQ) TOWER TO COOL PRIMARY FUMES FROM 1200 DEG. C TO 280 DEG. C

PLC CONTROLEED WATER PUMPING & COMPRESSED AIR

VALVE STAND

SPRAY LANCE INSTALLATION AT GCT

GAS COOLING TOWER (GCT)

FUME EXTRACTION SYSTEM : 1x 30T EAF + 1x30T LRF AT MUSCAT STEEL MELTING CO. LLC. , MUSCAT, OMAN

TECHNICAL PARAMETERSTECHNICAL PARAMETER : FUME EXTRACTION SYSTEM : 1x30T EAF + 1x30T LRF

Volume of Fumes 5,10,000 Am3/Hr at 1100C at each Bag-house Inlet Fixed Elbow Duct to Combustion Chamber Tubular; 1450 mm Dia. x 6.0m LCombustion Chamber Tubular; 2600 mm Dia. x 5.5m LWater-cooled Duct up to Forced Draught Cooler (FDC) Tubular; 1350mm Dia. x 45.0m LAir cooled Duct [Secondary Canopy to Mixing Chamber ] ID 2600mmAir cooled Duct [ LF to Sec. Duct ] ID 600mm Air cooled Duct [Mixing Chamber to Bag-house ] ID 2400mm Air cooled Duct [Bag-house to ID Fan] ID 2800mmTemp. at inlet of Forced Draft Cooler 500 - 550 0CTemp. at Outlet of FDC 220 - 250 0CFume Temp. at ID Fan Inlet 110 0CStack Dia. - 3400mm x 45.0m L

Forced Draft Cooler (Horizontal type) Cooling Air in tube and hot dirty fumes on tubes outer

surface (3x22KW Motors for Centrifugal Fan)

Bag House

1 No. (Capacity: 5,10,000 Am3/hr ) Pulse Jet Cleaning – Off Line Non-Woven Type Polyester, PTFE Treated A to C Ratio (Net) : 1.3 m3/m2/minute Pr. drop across BH : 150 mm WC Clean Gas dust content : 10mgm/Nm3


1 No. 20,000 Am3/hr. at 140 0C ; Static Pr. : 300mmWC 30 KW @ 990rpm; 415V


3 Nos. (2 Nos. running +1 No. Stand-by) 2,55,000 Am3/hr. at 120 0C ;Static Pr. : 600mmWC; 600 KW @ 990rpm; 415V; with Soft Starter

FUME EXHAUST EXTRACTION SYSTEM : 1x 30T EAF + 1x30T LRF AT MUSCAT STEEL MELTING CO. LLC. , MUSCAT, OMAN

FLOW SHEET

FUME EXTRACTION SYSTEM : 1x 30T EAF + 1x30T LRF AT MUSCAT STEEL MELTING CO. LLC. , MUSCAT, OMAN

GENERAL LAYOUT

FUME EXTRACTION SYSTEM : 1x30T EAF + 1x30T LRF AT MUSCAT STEEL MELTING CO. LLC. , MUSCAT, OMAN

FUME EXTRACTION SYSTEM : 1x 35T EAF + 1x35T LRF AT ARORA IRON STEEL , LUDHIANA

FES LAYOUTTECHNICAL PARAMETER : FUME EXTRACTION SYSTEM : 1x35T EAF + 1x35T LRF

Volume of Fumes 5,50,000 Am3/Hr at 1100C at each Bag-house Inlet Fixed Elbow Duct to Combustion Chamber Tubular; 1450 mm Dia. x 6.0m LCombustion Chamber Tubular; 2600 mm Dia. x 5.5m LWater-cooled Duct up to Forced Draught cooler Tubular; 1350mm Dia. x 45.0m LAir cooled Duct [Secondary Canopy to Mixing Chamber ] ID 2600mmAir cooled Duct [ LF to Sec. Duct ] ID 600mm Air cooled Duct [Mixing Chamber to Bag-house ] ID 2400mm Air cooled Duct [Bag-house to ID Fan] ID 2800mmTemp. at inlet of Forced Draft Cooler 500 - 550 0CTemp. at Outlet of FDC 220 - 250 0CFume Temp. at ID Fan Inlet 110 0CStack Dia. - 3400mm x 35.0m L

Forced Draft Cooler (Horizontal type) Cooling Air in tube and hot dirty fumes on tubes outer

surface (3x22KW Motors for Centrifugal Fan)

Bag House

1 No. (Capacity: 5,50,000 Am3/hr ) Pulse Jet Cleaning – Off Line Non-Woven Type Polyester, PTFE Treated A to C Ratio (Net) : 1.3 m3/m2/minute Pr. drop across BH : 150 mm WC Clean Gas dust content : 30mgm/Nm3


1 No. 25,000 Am3/hr. at 140 0C ; Static Pr. : 300mmWC 37 KW @ 990rpm; 415V


3 Nos. (2 Nos. running +1 No. Stand-by) 2,75,000 Am3/hr. at 120 0C ;Static Pr. : 550mmWC; 600 KW @ 990rpm; 415V; with Soft Starter

FUME EXTRACTION SYSTEM : 1x 35T EAF + 1x35T LRF AT ARORA IRON STEEL , LUDHIANA

FES LAYOUT

GAS CLEANING SYSTEM GAS CLEANING SYSTEM FOR 1x35T VACUUM DEGASSING UNIT

AT ARORA IRON STEEL , LUDHIANA

a) Air flow rate at Bag Filter inlet : 60,000 m3/hr at 0.67 mbarb) Type of Bag Filter : Circular Pulse Jet Cyclonicc) Air temperature at the Bag filter inlet : 60 deg C d) No. of bags : 112 nos. 150 mm dia x 4000

mm longe) Filter media selected : PES with P84 on topf) Total Filter Surface Area : 211m2

g) Pressure drop across bag filter : 0.12 mbarh) Dust loading at filter inlet : Please specify

i) Dust emission limit : 30 mg/Nm3 j) Dust composition : Fines of metal oxides k) Dust properties : Free flowing l) Bag Filter Design criteria : To suit surge pressure of

600 – 800 mbar.

FUME EXTRACTION SYSTEM : 1x 60T AOD AT SALEM STEEL PLANT

LANCE CARRIAGE SYSTEM

MOVABLE DUCT WITH CAR

WATER-COOLED DUCT

WATER-COOLED COMPONENTS FOR FUME EXTRACTION SYSTEM : FOR LD-2 AT TATA STEEL

PORTION OF WATER COOLED HOOD

SKIRT WITH WATER-COOLED RING

AT TATA STEEL PROWESS CAN OFFER FOLLOWING POLLUTION CONTROL SOLUTIONS

Pollution Control Measures at Mines

Dust Emission Control at Stock House

Dust Suppression & Extraction System at RMHS of various plants like Coke Oven Plant, Sinter Plant, Lime Plant etc.

Cast House Fume Extraction System using VVVF Drives for ID Fans

Modification & Up gradation in existing system to meet latest pollution norms.

Reverse Engineering and Spares Supply for existing systems.

THANK YOU !!!THANK YOU !!!

pollution control solutions prowess-2k16-1-1

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