Noviembre 2006

Seminario Internacional Soluciones 2006

Santiago de Cali, Colombia 2 y 3 de Noviembre de 2006

Noviembre 2006

Soluciones de Aire Limpio en la Industria del Hierro y el Acero

Linda Ayala y Nelson Izquierdo

Environmental Control Systems

Our Business

Air pollution control systems & products for power & industrial applications A business driven by increasingly strict emissions regulations Serving new plants & retrofitting existing plants

Bringing you a World of Experience in Clean Air Solutions

Environmental Control Systems

Our Organization

Employs around 1000 air pollution control professionals Located in 13 countries around the world Dedicated R&D facilities 70 years experience in air pollution control

ALSTOM Environmental Control Systems Origin and background:

1922 1989 1999 2000

1996

Daneco
Italy

- Long history in air pollution control -

Our Locations
Oslo Vxj Helsinki Moscow Paris Milan Kobe Beijing

Butzbach Knoxville

Kolkata So Paulo Sydney

Total: approx. 1000 employees ECS Corporate Headquarters + French Unit, Paris, France

Our Locations

Latin America
New Office Locations
Caracas

Mexico

Bogot

Santiago

So Paulo Buenos Aires

ECS

LAM Headquarters

Industries we Serve

Aluminium Cement Glass Iron & Steel Industrial Incineration Plants Non-ferrous Pulp & Paper Power

Iron & Steel at a Glance

Leading position worldwide as supplier of APC plants for the Iron & Steel Industry. Over 30 years experience More than 600 successful installations world wide 280 references for Electric Steel Shop / Mini Mill 320 references in Integrated Steel Plants Technical excellence achieved by long experience and focused R&D efforts

Electric Steel Shop / Mini Mills

Scope of Business - Air Pollution Control:
Electric Arc Furnace (E.A.F.) - primary & secondary emissions Argon Oxygen De-carbonisation (A.O.D.) converters primary & secondary emissions Ladle Furnace (L.F.) - primary & secondary emissions

Scope of Business - Noise Proofing System:

Dog-house enclosure for E.A.F. Elephant-house enclosure for E.A.F.

Integrated Steel Plants

Scope of Business - Air Pollution Control:
Sinter band (primary & secondary emissions) Dedusting with Electrostatic precipitator or Fabric Filter SO2 and dioxin control with NID (dry de-SOx) Pelletising plants Secondary ventilation for stock house Secondary ventilation for converter and mixer hall Coke pushing de-dusting Lime kiln de-dusting Blast Furnace cast house ventilation

Product Portfolio
In House technology:
Water-Cooled Hoods and Ducting Post-combustion Chambers Gas Coolers - forced-draft and natural-draft types Hot Quenching Towers Hoods for secondary emissions Cyclone & spark-arrestors - axial and vertical types Fabric Filters (FF) - pulse-jet and reverse-air types Electrostatic Precipitators (ESP) - dry and wet types Wet Scrubbers

Scope of Activities
Equipment and system supply: Supply of complete plants Supply of dedicated Products Turn-key installations of dedicated Products Modernisation and retrofit of existing installations

Scope of Activities
Services: Engineering service for complete plants and for dedicated Products Supervision service to erection, start-up and commissioning Post start-up services (i.e. spare parts, technical assistance, etc.)

Iron & Steel - references

List of recent references:

Project Process Contract

Aceralia - Gijon, Spain - 2 ESPs for sinter primary gases 06 / 2004 Arcelor - Fos sur Mer, France - FDA for sinter primary gases 01 / 2004 Mechel, Chelyabinsk, Russia - 4 ESPs for sinter primary gases 01 / 2004 Gerdau-Cosigua, Brazil - EAF primary and secondary gases 11 / 2003 Gerdau-Sao Paolo, Brazil - EAF primary and secondary gases 11 / 2003 Outokumpu-Tornio, Finland - EAF primary and secondary gases 06 / 2003 Rautaruukki-Raahe, Finland - BOF and mixer secondary ventilation 05 / 2003 Concast-EASRCO, Egypt - EAF primary and secondary gases 03 / 2003

Selected references

Rautaruukki Raahe Finland Mixer hall secondary ventilation start up 2004

Arcelor Dunkerque FRANCE Sinter band (Secondary) start up 2000

Selected references

Henningsdorfer Elektrostahlwerke GERMANY EAF and LF (Primary & Secondary) start up 1992

Outokumpu Stainless Tornio Finland EAF (Primary & Secondary) LF (Primary) AOD (Primary & Secondary) start up 2003

Selected references

Elbe Stahlwerke GERMANY EAF and LF (Primary & Secondary) start up 1992

Acerinox SPAIN EAF (Primary & Secondary) start up 1997

Selected references

Gerdau Piratini BRAZIL EAF and LF (Primary & Secondary) start up 1999

ALPA (Riva Group) FRANCE EAF (Primary & Secondary) start up 2000

Noviembre 2006

Linda Ayala y Nelson Izquierdo

Integrated Steel Plants at a Glance

More than 300 references globally Combination of air pollution control and process know-how Leading supplier for Sinter Band air pollution control No. 1 supplier of ESPs for sinter band Breakthrough technology for gas cleaning using dry FGD (SOx , HCl and dioxin removal) Technical excellence achieved by long experience and focused R&D efforts

- Integrated Steel Plants -

Integrated Steel Plants

Scope of Business - Air Pollution Control: Sinter band - primary & secondary emissions
Dedusting with Electrostatic precipitator or Fabric Filter SO2 and dioxin removal with NID/FDA

Pelletising plants Secondary ventilation for stock house Secondary ventilation for converter and mixer hall Blast Furnace cast house ventilation Coke pushing de-dusting Lime kiln de-dusting - Integrated Steel Plants -

Integrated steel plants

Sinter band - primary and secondary gases

- Integrated Steel Plants -

Integrated steel plants - Sinter band Sinter band - primary and secondary gases Traditionally ESPs used for primary de-dusting and fabric filter for secondary de-dusting Proven technology - references
more than 50 ESPs in operation for sinter primary more than 70 installations (ESP and FF) of sinter secondary

ESP collecting efficiency strongly related to chloride content in dust - Integrated Steel Plants -

Integrated steel plants - sinter band ESP emission comparison - sinter primary gases
CST Brazil Production rate (ton/h) Gas flow (Nm3/h) ESP type ESP control Start up year Measured emission (mg/Nm3) Comments
680 1 230 000 3-field EPIC II 1997 < 30 Very low chloride content Dust bleed of

ARCELOR - Ougree ARCLEOR - Charleroi Belgium

750 1 100 000 3-field EPIC II 1996 < 100

Belgium
310 500 000 4-field EPIC II 2002 < 100 Micropulse in 4th field

- Integrated Steel Plants -

Integrated steel plants - Sinter band ESP performance improvements Reduce load of alkali chlorides to ESP
Reduce feed of raw materials with high Cl content to sinter band. Reduce re-circulation of ESP dust (dust bleed of)

Advanced energisation
Advanced ESP control technology (EPIC II) Power down rapping Semipulse Micropulse Technology

Reduction of dust resistivity

SO3-injection

Integrated steel plants - Sinter band ALSTOM is forerunner in developing flue gas cleaning of sinter band primary gases
More stringent requirements for SOx, HCl, HF, Heavy Metals and Dioxins ALSTOM Research and Development Filosorption for dioxin removal - extensive pilot testing at site in Arcelor-Ougree site FDA/NID technology for dioxin and acid gases removal site testing, 1st installation start up in May 2005

- Integrated Steel Plants -

Integrated steel plants - Sinter band FDA/NID - single unit operation to control HCl, HF, SOx, Heavy metals and Dioxin
TC

ESP or Fabric Filter

Acid gases and dioxin removal Lime and activated carbon as reagents Extremely low particulate emission Compact design with small footprint No effluent, dry end-product
Water Recirculation

Few, simple and well proven components

Humidifier

Reagent End Product

- Integrated Steel Plants -

Integrated steel plants - Pelletising Electrostatic precipitator (ESP) for de-dusting Low pressure drop (250 Pa) Low investment and maintenance cost even for large gas flows High availability >99%

- Integrated Steel Plants -

Integrated steel plants

Coke oven batteries - coke pushing dedusting

- Integrated Steel Plants -

Integrated steel plants - coke pushing Patented trav-l-vent technology for fume capturing
Excellent alternative when retrofitting the existing coke batteries Effective & efficient capture of fumes during door opening and pushing sequence Reduced air volume enables savings in Fabric Filter size Compliance with Authority Rules for coke pushing emission control

Trav-LVent car Belt

Coke guide top suction

Trav-LVent duct Quench car hood

Coke guide front suction

- Integrated Steel Plants -

Integrated steel plants - coke pushing

In house competence for effective fume capturing Complete system with in-house technology Movable TRAV-L-VENT fume capturing hood Spark arrestor Fabric Filter Opacity increase during pushing sequence maximum 20% Stack emission guarantee is 10 mg/Nm3

- Integrated Steel Plants -

Integrated steel plants - coke pushing High efficiency dedusting - ALSTOM LKPB

Spark arrestors ensures reliable and safe operation Safety dampers for unexpected process situation ( green push ) Fabric filter design based on ALSTOM world class technology Pulse jet or reverse air fabric filters

- Integrated Steel Plants -

Integrated steel plants

Secondary ventilation

- Integrated Steel Plants -

Integrated steel plants

Secondary ventilation - number of references
Blast Furnace cast house ventilation 28 Fabric Filter references 26 ESP references Mixer and Converter secondary ventilation 28 Fabric Filter references Stock house ventilation 7 Fabric Filter references Material handling 20 Fabric filter references

- Integrated Steel Plants -

Integrated steel plants

Secondary ventilation - the solution What is required to have a efficient de-dusting?
Proper hood arrangement (lay out, placement, tilting/stationary)

Correct gas flow at each suction point Total gas flow (mixing of the gases from various sources) Control system - different process phases to be respected Selection of de-dusting equipment - ESP or FF

Guarantees achieved at working areas and at stack Satisfied customer

Integrated steel plants

Secondary ventilation - ALSTOM s competence Tailor made hood arrangement for each single sources Computerised Flow Dynamics (CFD) modelling used in hood design Fabric Filter typically used for de-dusting Low dust emission achieved (<10 mg/Nm3)

- Integrated Steel Plants -

Iron & Steel - references

List of recent references for integrated steel plants:

Project Process Contract

Aceralia - Gijon - 2 ESPs for sinter primary gases 06 / 2004 Arcelor - Fos sur Mer, France - NID for sinter primary gases 01 / 2004 Mechel, Chelyabinsk, Russia - 4 ESPs for sinter primary gases 01 / 2004 Rautaruukki-Raahe, Finland - BOF and mixer secondary ventilation 05 / 2003

- Integrated Steel Plants -

Recent references - sinter primary

ARCELOR - Fos Sur Mer, France Sinter primary gases FDA/NID system with activated carbon and lime injection Gas flow 800 000 m3/h Emission guarantees
Dust 50 mg/Nm3 SOx 225 mg/Nm3 Dioxin 0,1 ng/Nm3

Start up May 2005 - Integrated Steel Plants -

Recent references - Pelletising

COMPANHIA VALE DO RIO DOCE (CVRD) Location: So Luiz - MA, Brazil Gas flow : 2 365 000 Nm3/h ESP-type: 2 +1 ESP's, 3 field ESP-control: EPIC II Start up: 2002 Inlet dust concentration: 1 500 mg/Nm3 Guaranteed emission: 70 mg/Nm3
Two ESPS for windboxes and one for hood.

- Integrated Steel Plants -

Recent references - sinter primary

ARCELOR - Aceralia, Spain Contract signed in June 2004 ESP for Sinter band A (375 ton/h) Gas flow 800 000 m3/h 4 field ESP Micro-pulsing energisation Emission 50 mg/Nm3 Turn key installation Start up June 2005

- Integrated Steel Plants -

Noviembre 2006

Linda Ayala y Nelson Izquierdo

Mini Mills at a Glance

In-house technology for complete (primary and secondary gases) air pollution control systems Technology originated from Daneco and Flkt 280 references within Electric Steel Shop / Mini Mill more than 80 complete plant installed for E.A.F. References at all continents

- Electric steel shop / Mini Mill -

Mini Mills at a Glance

Recent product developments/improvements Hot Quenching Tower - up flow design Computerised Flow Dynamics (CFD) modelling for canopy hood Fabric Filter cleaning valve design - patented OPTIPOW cleaning valve

- Electric steel shop / Mini Mill -

Electric Steel Shop / Mini Mill

Scope of Business - Air Pollution Control:
Electric Arc Furnace (E.A.F.) - primary & secondary emissions Argon Oxygen De-carbonisation (A.O.D.) converters - primary & secondary emissions Ladle Furnace (L.F.) - primary & secondary emissions

Scope of Business - Noise Proofing System:

Dog-house enclosure for E.A.F. Elephant-house enclosure for E.A.F.

- Electric steel shop / Mini Mill -

Electric Steel Shop / Mini Mills

E.A.F - primary and secondary de-dusting

- Electric steel shop / Mini Mill -

Cooling of primary gases

Water Cooled Ducting (W.C.D.) - efficient cooling & energy production
High pressure design (12 bar) enables more efficient energy production Combustion chamber is water cooled ducting integrated to

W.C.D. length is highly dependent on cooling method downstream of the ducting (draft coolers vs. hot quenching tower)

- Electric steel shop / Mini Mill -

Cooling of primary gases

Water Cooled Ducting - Typical design features
Flue gas temperature (HQT downstream of WCD): Inlet: 1600 C Outlet: 900 C Flue gas temperature (Draft type Cooler downstream of WCD): Inlet: 1600 C Outlet: 500 C Water temperature (low pressure, 2-4 bar): Inlet: 50 C Outlet: 60 C Water temperature (low pressure, 8-10 bar): Inlet: 80 C Outlet: 110 C

- Electric steel shop / Mini Mill -

Cooling of primary gases

Hot Quenching Tower (H.Q.T.):

- Electric steel shop / Mini Mill -

Cooling of primary gases

Hot Quenching Tower - design features
Two media nozzles Typical flue gas temperatures Inlet: 900...1000 C Outlet: 250...350 C
Design is optimised by using CFD tools

Both up-flow & down-flow design available Up-flow design enables more efficient lay out >> savings in investment

- Electric steel shop / Mini Mill -

Cooling of primary gases

H.Q.T. - Advantages :
Primary fumes quick cooling with the injection of finely atomised droplets of water. The high amount of the water evaporation heat allows the cooling of the fumes with a reduced amount of water. Avoid the PCDD de-novo synthesis with the immediate cooling of the fumes below 250 C just after the combustion chamber. Connection of the primary fumes ducts to the secondary ventilation ducts just at short distance from the EAF, resulting in a more compact layout.

- Electric steel shop / Mini Mill -

Cooling of primary gases

H.Q.T. vs. Draft coolers :
No need of installation of very long Water cooled Ducts, with the consequent reduction of the Water Treatment Plant Power consumption and running cost. No need of Forced or Natural Draft Cooler reducing the system pressure losses (and consequently the main fan power consumption), and avoiding dust clogging in the cooler s tubes. Very easy cleaning operations. Rarely maintenance operation.

- Electric steel shop / Mini Mill -

Cooling of primary gases

Typical design features for HQT :
Acc. di Verona 1 Riva Group (Italy) GAS FLOW PRESSURE AIR PEAK Nm3/h 130.000 Nm3/h 2.400 35 850-275 2.300 / 8.350 0.41 Up Flow Acc. di Verona 2 Von Moss Stahl Riva Group (Switzerland) (Italy) 130.000 2.400 35 850-275 2.300 / 8.350 0.41 Up Flow 100.000 2.200 28 800-250 3.000 / 7.500 0.67 Down Flow Acc. Stefana (Italy) 200.000 4.600 60 950-250 ALPA France Riva Group (Italy) 110.000 2.850 40 935-265 ACIPco (USA) 190.000 2.800 52 1.000-350 2.500 / 40.000 1.03 Horizontal Flow

WATER PEAK m3/h TEMPERAT. IN/OUT HQT DIAM./H RETENTION TIME HQT TYPE C mm sec

4.000 / 13.000 3.000 / 12.000 1.04 Down Flow 0.98 Up Flow

- Electric steel shop / Mini Mill -

Electric Steel Shop / Mini Mills

E.A.F - primary and secondary de-dusting

- Electric steel shop / Mini Mill -

Cooling of primary gases

Natural - and Forced Draft - Coolers

Natural draft cooler

Forced draft cooler

- Electric steel shop / Mini Mill -

Cooling of primary gases

Natural - and Forced Draft - Coolers Cleaning of the pipes essential important for efficient cooling and prevention of clogging Typically used in processes with good scrap quality and stainless steel mills Forced draft coolers requires smaller footprint compared to natural draft coolers.

- Electric steel shop / Mini Mill -

Electric Steel Shop / Mini Mills

E.A.F - primary and secondary de-dusting

- Electric steel shop / Mini Mill -

Secondary ventilation - canopy hood

Canopy hood - tailor made design
Optimised design for effective suction during all process sequences CFD modelling based design Proven technology with more than 70 installations world wide

- Electric steel shop / Mini Mill -

Safe operation
Spark arrestors and safety dampers
Optimised pressured drop (400 - 700 Pa) Efficient reduction of glowing particles Enables safe operation for FF Double safety dampers gives extra safety for FF operation

- Electric steel shop / Mini Mill -

De-dusting
Fabric Filter - heart of the cleaning system
ALSTOM is the leading fabric filters supplier More than 200 fabric filter installations in Iron&Steel industry Both reverse air or pulse jet type fabric filter in product portfolio Patented OPTIPOW cleaning valve design for pulse jet FF EFFIC control system with broken bag detection Excellent reliability and availability

- Electric steel shop / Mini Mill -

Noise enclosures

RESPECT: Noise limits of 85 dB(A) in working areas Noise limits of 45 dB(A) in facilities boundaries

Noise enclosure SOLUTIONS that can:

retrofitted to existing meltshops, or adapted to new plant layouts

Recent references

List of recent references for Mini Mills:

Project Process Contract

Gerdau-Cosigua, Brazil - EAF primary and secondary gases Gerdau-Sao Paolo, Brazil - EAF primary and secondary gases Outokumpu-Tornio, Finland - EAF primary and secondary gases Concast-EASRCO, Egypt - EAF primary and secondary gases De Acero-Saltillo, Mexico - EAF primary and secondary gases

11 / 2003 11 / 2003 06 / 2003 03 / 2003 11 / 2002

- Electric steel shop / Mini Mill -

Recent references
Outokumpu Stainless Tornio - Finland
EAF (150tons) Water cooled ducting Forced draft coolers Canopy hood Spark arrestor Fabric Filter AOD (150 tons) Water cooled ducting Forced draft coolers Canopy hood Spark arrestor Fabric Filter Ladle furnace Canopy hood Fabric Filter

- Electric steel shop / Mini Mill -

Recent references
De Acero S.A. - Saltillo EAF (55 tons) primary and secondary gases Refurbishment of the existing flue gas treatment Start up 2003 Delivery consisted: New Hot Quenching tower - up-flow design Additional fabric filter - pulse jet type ID fans

- Electric steel shop / Mini Mill -

Recent references
Gerdau - Sao Paolo EAF (100 tons) and LF primary and secondary gases Complete flue gas handling system consisting
Water Cooled ducting Hot Quenching tower - up-flow design Canopy hood for capturing secondary fumes Spark arrestor Reverse air type of fabric filter (700 000 m3 /h) ID fans (2 * 1200 kW) Stack

Start up 2005

- Electric steel shop / Mini Mill -

Recent references
Gerdau - Cosigua EAF (170 tons) primary and secondary gases Rebuilding of existing flue gas treatment
Hot Quenching tower - up-flow design Spark arrestor Extension of existing Reverse air type of fabric filter

Start up 2005

- Electric steel shop / Mini Mill -

www.environment.power.alstom.com

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