Académique Documents
Professionnel Documents
Culture Documents
Quick Info
MELTSHOP DESIGN
From Water Cooled Panels to complete Electric Arc Furnaces, from Ladles to complete
Ladle Furnaces, from Tundishes to complete Continuous Casting Machines, from Ducts
to complete Fume Treatment Systems and from Engineering Services to Turn-Key
Plants, CVS offers economically viable solutions at European standards.
CVS - EAF
Design Main Objective
Increasing productivity
while improving energy
efficiency.
Meet environmental
requirements at a
minimum cost.
Better coordination of
process/environmental
requirements
CVS - EAF
Typical Furnaces
CVS - E.A.F.
Mechanical Design Features – 1/2
The EAF is of “Full Platform” type i.e. with electrode lifting column support
and the roof lifting and turning machinery mounted on the tilting platform.
Electrode lifting columns and electrode arms of stiff design allowing for
fast 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 to
balance out the weight of the column, arm and power cables.
CVS - E.A.F.
Design Benefits
Main benefits
Increased productivity due to shortest melting and idle times
High power input (up to 1 MVA/t)
High-impedance furnace
Arc voltage up to 1,500 V
Proven low-consumption values energy, electrodes, refractories, etc.)
Low tapping temperatures and minimum slag carry-over
Minimum maintenance with the use of heavy mill-type components
Highest flexibility with respect to charge materials
CVS - EAF
Chemical Energy System Concept
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 hydrocarbon
burner, all in the same housing.
Three jet burners are installed in the upper shell’s side wall, while the forth one
is located in the EBT area. The functions of the injection system are :
CVS - EAF
Burner Design Concept
The location and the direction of the burners are determined to reduce the cold
spots effect generated by the three-phase arc of the furnace, thus obtaining an
even and faster melting.
CVS - EAF
Burner Positioning Inside Furnace
The lance manipulator for the Electric Arc Furnace is primarily designed for
safe oxygen injection. As well, solid materials like Carbon can be given from
burner case.
CVS - EAF
Burner Advantageous
CVS - EAF
Burner Flame Shape Management
In addition, an electrical arc covered by a foaming slag will have a higher efficiency in
transferring the energy into the steel phase.
CVS -
Slag Foaming
O2 + 2 Fe = 2 (FeO)
(FeO) + C = Fe + CO (g)
CVS have big experience for manufacturing of Furnace panels made of copper and
steel.
CVS - EAF
Typical EAF Layout
CVS - EAF
Typical 3-D View
CVS - EAF
Typical 3-D View
CVS - EAF
Typical Section View
CVS - EAF
Roof Lifting Operation
•Saving of ferroalloy
•Saving of energy
•Increase productivity
low content of harmful elements such as sulphur, phosphorus, trace elements and/or
carbon,
PURPOSE
• H removal
DESIGN FEATURES
• N removal
• S removal • Dimensioning of vacuum tank
• C removal (VOD) • Vacuum hopper
• Dust separator
RESULTS
• H contents < 1 ppm
• N contents -30/50 %
• S contents -80/95 % VACUUM PUMP FUNCTION
• C contents < 20 ppm • Function of a steam ejector
• Compression of off-gas with ejectors in
series
PROCESS
• Intermediate condensation of motive
•Temperature loss during steam
vacuum treatment • Waterring pumps
• Global function of ejectors and
condensers
LAYOUT
• Longitudinal section • Process flow diagram 5-340 WR
• Vacuum pump • Suction capacity of pump 5-340 WR
CVS - SECONDARY METALLURGY
VD / VOD Plant
Hydrogen Removal
The final hydrogen content of a heat depends on the pressure of vacuum vessel, the amount
of the purging gas and the CO-gas development.
Even fully killed heats can be treated due to intensive degassing supported by lift gas. For
lowest hydrogen levels the pressure must be lower than 1 mbar with according treatment
times of 15 - 20 min depending on the starting level.
Nitrogen Removal
Even in VD-Plants nitrogen removal is preferably carried out. Having low sulphur and
oxygen levels this process as well requires low vacuum levels with less than 1mbar for
approx. 15 - 20 min.
Argon is purged by the porous plugs from the ladle bottom with approx. 10 Nl/(min, t steel).
The final sulphur content of a heat depends on the pressure of vacuum vessel, the
amount of the purging gas and the amount of synthetic slag added prior to vacuum
treatment start. The EAF furnace slag has to be reduced during tapping to values below or
equal to 5 kg/t Steel.
For low sulphur levels the pressure must be lower than 1 mbar with according treatment
times of 15 - 20 min depending on the starting sulphur level. Argon purging by the porous
plug from the ladle bottom with approx. 10 Nl/(min, t steel) has to be ensured.
The liquid steel will be tapped unkilled or semi-killed from the EAF and partly deoxidised
in the VD-plant.
The deoxidation will occur due to the CO-development by natural decarburisation. The
pressure 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 METALLURGY
VD / VOD Steam Ejector Pumps
Condenser
Booster/ejector
Vacuum Vessel
- Desulphurisation
VOD
VOD PROCESS CONTROL
-Calculation functions
- Thermodynamic model
- Example of oxygen blowing 0 0.5 1.0
CARBON CONTENT
THERMODYNAMICSC - removal at low pCO and high temp
1700
1680 100.0
Reduction
1660 Oxygen
Agents
Temperature, C
Pressure, torr
1640 Slagbuilding, Alloying 10.0
Heating
1620
1600 1.0
1580
Trim
1560 Additions 0.1
1540
1520 0.0
0 20 40 60 80 100 120 140 160 180 200
Time, minutes
This gas stirring system is designed to feed inert gas through a refractory lance for
emergency stirring if the porous plug does not work properly.
The refractory lance is held and plunged into the steel bath by a structure adjacent to
the ladle roof.
CVS - Liquid Steel Auxiliaries
Ladle Preheaters / Driers
The burner creates a high-velocity, extended flame, which brings the thermal energy
down to the ladle bottom.
The combustion air is generated by a centrifugal fan located in a protected position in the
burner stand and led via the cover suspension arm to the burner.
The hydraulic power for lid movements is provided by an independent hydraulic power
pack.
The burner is directly ignited by means of a high voltage device after automatic purging
of the combustion chamber.
CVS - CCM
General description
Steel from the electric arc furnace is tapped into a ladle and taken to the continuous
casting machine. The ladle is raised onto a turret that rotates the ladle into the
casting position above the tundish. Liquid steel flows out of the ladle (1) into the
tundish (2), and then into a water-cooled copper mold (3). Solidification begins in
the mold, and continues through the First Zone (4) and Strand Guide (5). In this
configuration, the strand is straightened (6), torch-cut (8), then discharged (12) for
intermediate storage or hot charged for finished rolling.
CVS - CCM
Design Concept
CCM can be designed to produce square billets in the sections between 100 to 160
mm2, and blooms between 180 to 260 mm2.
Special designs for beam blank and round sections between 160 to 440 mm can be
done.
Radius of 5-12 meter and mould length of 750-1000 mm can be designed according to
project 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 the
production schedule given by the EAF.
According to customer request, CCM can be equipped with the necessary modern
equipment to produce high quality casted products, such as tundish of delta type to
reduce inclusions in the mould, long copper tube to improve primary cooling on the
billet surface, automatic mould level control system, high casting radius to reduce
stress during unbending, secondary spray cooling divided in three zone for a better
cooling effect and control, walking beam cooling bed for the straightening of the long
billets.
CVS - CCM
Design Concept
CVS - CCM
Quick Nozzle Changer
CVS - CCM
Quick Nozzle Changer Profits
– Better billet quality thanks to Quick nozzle change device in the CCM can
keeping a constant casting increase the number of heats in sequence:
speed
– Up to 75% of tundish refractory 99,5
consumption saving up to 99
0,7US$/ton 98,5
98
– Up to 80% of metallic losses
97,5 single heat
reduction due to a reduction of
head/tail crops and tundish skull 97 short sequence
saving up to 0,8US$/ton 96,5 long sequence
– Reduction of tundish 96
maintenance people because of 95,5
Reduction by 5 times the 95
number of tundish used Material yield
– Increase of the metallic yield of
the caster up to 0.5%
CVS - CCM
Typical Sectional View
CVS - CCM
Typical Sectional View
CVS - CCM
Typical View
CVS - CCM
Ladle Turret
Serving to support the teeming
ladle and adjust it to casting
position.
Weighig Load-cells
Different Designs
Ladle Car
Ladle Rotation Arm
Liftible Ladle Turret
Independent Arm Ladle Turret
CVS - CCM
Tundish Car
Weighig Load-cells
CVS - CCM
Mould 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-mechanical
Hydraulic
Air spring
Mechanical Spring
CVS - CCM
Secondary Cooling
CVS - CCM
Withdrawal and Straightener
CVS - CCM
Dummy Bar
- Rigid design
-Safe operation
CVS - CCM
Lateral Transfer System
CVS
SCRAP BUCKET PRESS
UP TO 60 % INCREASE IN THE
SCRAP DENSITY IN SCRAP BUCKET
THANKS TO THE HYDRAULIC FORCE
UP TO 250 TON LOAD.
CVS - SCRAP BUCKET PRESS
WHY TO CHOOSE
- Easiest Installation
-Improved productivity
PRESS OPERATION
PARK POSITION
CVS - SCRAP SHEAR
The design of the CVS press shears is based on the concept with cylindric guides for the
shear head ensuring a precise cut between the upper and lower blades.
The shear is build within a robust, twist resistant welded construction allowing
installation directly onto concrete without anchorage and therefore having low foundation
costs.
The shear is equipped with a hydraulically operated filling box which allows charging of
the shear during production. This design decreases the charging time and increases the
productivity.
The machined pressing box ensures the precise movement of the compactors as well as
fast and stick free pre-compaction of bulky scrap.
The extra long vertical holder guides allow the scrap that has been pre-compacted by
the side-compactor to be pressed against the lowered vertical holder, allowing bales can
be produced as well.
Main Profit:
CVS -
Scrap preheating Systems
-Easy Solution
-Better Operation
-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 the
total 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 bucket
before charged into an EAF and thus contributes towards energy saving.
Gas evacuated from the EAF is led to a combustion chamber through a suction duct
together with air induced through gap between EAF elbow and sliding sleeve duct to burn
CO contained in the gas, a part of this burned gas is introduced in to the bucket placed at
the scrap to heat scrap. After passing the bucket, the gas is returned to the combustion
chamber 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 be
sent 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 mixing
with 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, special
sealing devices are provided between hood pipe and inlet duct, hood and scrap bucket
top edge, bucket cylinder and clamp shells.
By use of the adequate sealing devices, air introduced into the scrap pre-heater is very
small.
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 additional
worker.
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 dust
collector system.
Proper adjustment of the preheating temperature prevents the scrap bucket from being
deformed.
CVS -
Carbon Handling System
CVS -
Carbon Handling System
Design Features Design Advantages
Up to 5.000 ton/month
Starting Carbon Low dust
Size: 0-100 mm Fast Pay-back
Humidity: Up to %25 Minimum Investment
End Product: Maintenance Free
Humidity: Less than 1 % Low operation Cost
3-8 mm Carbon (10-40 %) Higher productivity
0-3 mm Carbon (30-80 %) Safe Operation
Dust: Less than 6 % Fully-automatic
Energy Consumption: Adaptable for
Less than 8 kWh/ton C automatic feeding
NG Consumption:
Less than 30 Nm3/ton C
CVS - FTP
Design Concept
FTP DESIGN
From EAF Roof Elbow to Stack, CVS provides complete Fume Treatment Plants with
engineering, design, manufacturing and installation. Design considers also LF, MHS,
canoppy and other dust emitting points by the goal of ZERO DUST EMITION to
environment. CVS offers economically viable solutions at European standards.
CVS - FTP
Design Concept
CVS designs FTP to collect, suck and treat the primary and secondary emissions
generated by the EAF, the primary emission generated by the LF and the emission
emitted by the Material Handling System.
The dedusting system consists of a
set of fume collection points and a
set of ducting lines (water-cooled or
radiant type), which convey the
various emissions to the bag filter
already under implementation.
Melting phase
•EAF in melting phase (roof closed,
primary fumes suction line open);
•Suction from the canopy hood to
provide meltshop ventilation and
primary fumes cooling;
•LF in heating phase;
•MHS in operation.
Charging/Tapping phase
•EAF in charging/tapping phase (roof
open, primary fumes suction line
closed);
•Suction from the canopy hood;
•LF in heating phase;
•MHS in operation.
CVS - FTP
Typical Filter Unit
CVS - FTP
Typical Canoppy Hood
CVS - FTP
Typical Pelletizer
CVS - FTP
Design Focus
Reliability
Reduced maintenance requirements
Reduced operating cost (electrical energy, compressed air)
Low residual dust content at stack
Low noise emission technology
Environment Friendly
AUX
STACK
CANOPY HOOD
W.C. DUCT
FAN FAN
BAG-FILTER
CYCLONS
COOLER
LF EAF SETTLING
CHAMBER
CVS - FTP
Typical Drawing
CVS -
Converter Off-Gas System
CVS -
Converter Off-Gas System
CVS - Material Handling System
CVS - MHS
Design Concept
a) Equipment for Ferro-alloys and additives storage from receiving hoppers to the
bins battery
c) Equipment for Carbon and lime extraction, dosing and weighing, transport and
charging into scrap buckets.
CVS - DRI Continuous Feeding System
Slag control, feeding rate and power input are the key factors in continuous charging
procedures.
CVS - DRI Continuous Feeding System
• A maximum briquette
dimension that is less than 50%
of the minimum hopper opening,
Slag has been recycled and effectively used as a base coarse material (road bed
material). Now, it is also possible to use soil-improvement material (for hardening of soft
ground).
-Removal of filler material from the fine fraction prior to the use of next step separators
Scope of services:
Perfect integration into the entire system is vital to ensure competitiveness in the
future. The implementation is always adapted to local legal requirements,
environmental protection conditions and customer standards.
climatic conditions
legal requirements.
These are partially determined by varying regional conditions. Thanks to our many
years of experience in the various regions of the world and our comprehensive
process knowledge in plant construction, we’re able to professionally incorporate
these localized, varying factors into the plant design.
Main benefits:
CVS -
Piping and Erection for Oxygen Plant
CVS - AUTOMATION
EAF – Arc Regulation System
Arc Regulation system (ARS) for
EAF applications is the latest
stage of development which
using PC based Windows XP
operating system.
CVS - AUTOMATION
EAF – Voltage & Current MeasuringSystem
Actual voltage and current of
furnace are read by special
analog/digital converter card
installed on the PC.
CVS - AUTOMATION
CCM – COOLING BED
CVS - AUTOMATION
FTP – COMBUSTION CHAMBER
CVS - AUTOMATION
FTP – CYCLONE & FILTER
ROLLING MILL DESIGN
From Bar mill to Section Mill, From Chimney to complete Reheating Furnaces, from
Roll Stands and water quenching system to complete Rolling Mill Train, from
Cooling Bed Area to Handling Area, from Flying Shears to Cold Shears, Full
Automation System and from Engineering Services to Turn-Key Plants, CVS offers
economically viable solutions at European standards.
- The discharge machine, called kick-off, controlled from the main pulpit.
The plant is designed according to the latest technology in the field of steel plant
machinery and equipment.
The layout takes full advantage of the rationality of material handling in the plant
in order to obtain the following results:
The layout of the meltshop and the location of Auxiliary Plants have been
carefully 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 the
achievement of the following high-priority objectives, namely:
Integrated online and offline process models reflect decades of practical experience
and help to ensure reliable, reproducible quality.
Our process engineering expertise fuses these products into complete plant solutions
that also accommodate the upstream and downstream processes.
These solutions are the basis for optimal resource use, minimized waiting times and
reduced maintenance and spare parts costs, as well as wide flexibility with respect to
raw materials and the resulting products.
CVS -
Training and Technology Transfer
Whenever CVS recieves an order for steelmaking equipment, engineering services and
know-how transfer are mutually agreed upon between both parties.
Thanks to our experience, there is no question that we know that this is fundamental
basis for succesful production equipment.
The main target of training on the customer’s site is to familiarise their personel with
hands-on operation ofthe supplied machines and equipment.
The operators and maintenance personel are trained step by step to prepare them for
successful operation of the equipment.
CVS -
Typical Learning Curve for Meltshop
900 100000
800
Nominal / month
83.333 ton (120 to)
90000
Typical
80000
expected
values:
700
70000
600 0,25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
T o n s / M o n th (liq u id )
4 198 428 548 586 657 670 733 730 762 619 540 674 591 729 698 751 709 796
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 60000 98.376
88.698
500
80%
H e a ts / M o n th
50000
400
40000
production rate
300
30000
after 8 months
200
20000
100 10000
100%
0 0
production rate
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 after 10 months
Months X
90 t/heat 120 t/heat
CVS -
Erection and Site Management
Steel Structure:
Shop drawings
Supervision of fabrication
For erection engineering, site management and site monitoring, our professional handling
of the site ensures the quality of the plant and guarantees adherence to both the budget
and the schedule.
In addition, our experts have experience in dealing and working together with people from
different cultural groups. With their social sensitivity, motivation and leadership ability,
they ensure a perfectly functioning site.
Our staff is well trained with regard to health and safety issues. Compliance with
international, local, customer and company regulations is mandatory, and is assessed on
a regular basis
CVS -
Erection and Site Management
Erection engineering & site management
Change management
Supervision of erection:
CVS -
Erection and Site Management
Main benefits:
Experienced engineers, site managers and supervisors with a well-founded and wide
range of state-of-the-art experience, as well as cultural awareness are available.
Single point coordination of the entire site activities including time scheduling for an
optimized erection time, and budget planning, ensures the lowest possible costs and
best possible quality.
CVS -
Turn-key Solution
CVS -
TOSCELIK PROJECT
CVS -
NURSAN EAF PROJECT
CVS -
NURSAN EAF PROJECT
TOSYALI holding was one of the leader company in Turkey especially in pipe
production. They decided to make new meltshop and rolling mill investment for
long production and slab production. They awarded CVS for comple turnkey
solution.
• 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
CVS -
QUALITY MANAGEMENT
PHILOSOPHY
CVS -
GENERAL POLICY
REFERENCES
REFERENCES
REFERENCES