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Tec
E N V I R O N M E N TA L P R E H E AT I N G
&
CONTINUOUS CHARGING SYSTEM
(EPC)
KR Tec C O M PA N Y P R E S E N TAT I O N
CVS TURKEY
CVS EUROPE CVS MIDDLE EAST CVS CIS
Italy‐Udine Egypt‐Cario Ukraine‐Donetsk
FROM CONCEPT TO COMMISSIONING
Design
Manufacturing
Erection
Training
Consultancy
Innovation
Process Development
CVS POLAND CVS IRAN CVS INDIA CVS S.KOREA CVS SINGAPORE CVS USA CVS GREECE
Warsaw Tahran Pune Seoul Singapore New York Athens
info@cvs.com.tr www.cvs.com.tr
KR Tec C O M PA N Y P R E S E N TAT I O N
CVS MAKINA has a cooperation with KR Tec company which has developed a New
Generation concept in Arc Furnace Steelmaking, ENVIRONMENTAL PREHEATING &
CONTINUOUS CHARGING SYSTEM (EPC).
Idea behind the challenge is to recover the heat lost to FTP system by the application of
Scrap Preheating.
One of the issues of the EPC System is to charge the scrap independent of the electric arc furnace
taken into consideration the environmental aspects.
The EPC System is installed beside the EAF and the preheated scrap can be charged continuously by
the telescopic feeder system in the melting chamber during Power On.
Even during charging of the scrap basket into the EPC System, the system is always airtight and a
small amount of dust can only escape. Furthermore, the design has been considerably simplified to
increase the reliability and the profitability of the investment, reducing the ROI by less than 12
months.
KR Tec A D VA N TA G E S
ENERGY SAVING
ENERGY SAVING
The EPC reduces the electric energy consumption by approx. 80‐100 kWh/t compared to the
conventional EAF.
INDEPENDENT SCRAP CHARGING
g g p p p y p
Charging of the scrap basket is done with power‐on and independently from the furnace operation.
This improves the operation and reduce the Power off time
HIGHER PRODUCTIVITY
Due to shorter power‐on and power‐off times. The productivity of the furnace can be increased by
min. 20 % compared to the conventional EAF.
HIGHER RETURN ON INVESTMENT
Th EPC System
The S t f t
features l
lower conversion
i costt due
d to t the
th preheating
h ti effect.
ff t Furthermore
F th hi h
higher
productivity because of less power‐on and power‐off are assured.
KR Tec R E S P E C T T O N AT U R E
MINIMUM DUST EMMISION
During charging procedure the system/pre‐heating chamber is always in airtight situation which
reflects a minimum of pollution in the meltshop.
LOW FTP CAPACITY REQUIREMENT
Fume Treatment System capacity is reduced thank to the completely closed operation and flat bath
condition.
LOW DOWNTIMES & MAINTENANCE
No critical mechanical parts such as fingers, conveyors, water cooling which cause unforeseen
stoppages and maintenance.
t d i t
ADAPTABLE TO CONVENTIONAL METHOD
Operation can be changed immediately to Conventional method by opening of the off gas bypass
Operation can be changed immediately to Conventional method by opening of the off gas ‐ bypass
flap.
LESS FLICKER
LESS FLICKER
Related to the flat bath operation, preheated scrap and the constant energy input, a reduced flicker
and less noise generation will be achieved.
KR Tec EPC SYSTEM
BENEFITS REGARDING ENVIRONMENT
Charging with closed system
h h l d
Minimum fume during scrap charging
Cleaner working area
30% less off gas
30% less off gas
30 % less dust at the filter
Less noise (melting of preheated scrap)
Respect of most environmental standards
Respect of most environmental standards
KR Tec EPC SYSTEM
FEATURES
Flat bath operation
Controlled scrap quantity input through telescopic feeder system
Charging during power on
Preheating temperature controlled by PLC
Minimized off gas volume related to airtight system
KR Tec EPC SYSTEM
The scrap basket will be charged into a drawer of the EPC system which is in waiting position.
While this position the front wall of the drawer is closing the preheating chamber and the
melting process in the EAF and preheating doesn`t have to be interrupted.
After filling of the drawer by the scrap basket a slide gate on top of the EPC System will be closed.
Than the drawer will be forwarded by hydraulic cylinders to the preheating chamber and the
scrap falls smoothly inside the pre‐heating chamber where it will be preheated.
If the drawer is in front position, the back wall of it, is closing to the pre‐heating chamber.
A special design of the off gas duct together with a water cooled regulation flap allows to control
the preheating effect in the pre‐heating chamber.
CHARGING HOPPER
KR Tec I N P R E H E AT I N G P O S I T I O N
KR Tec MAIN COMPONENTS
OFF GAS
R E G U L AT I O N
FLAP CHARGING
HOPPER
TELESCOPIC
SCRAP
FEEDER
SYSTEM
EPC -
SYSTEM
T R AV E L L I N G
FRAME
KR Tec MAIN COMPONENTS
KR Tec MAIN COMPONENTS
KR Tec EPC CHARGING HOPPER IN
Refining phase of EAF
‐Preheating of 1st bucket of next heat in pre‐heating chamber
‐Charging of next bucket into charging hopper
KR Tec PROCESS STEPS OF EPC
‐Moving of charging hopper into pre‐heating chamber
‐Preheating of 2nd bucket of next heat in pre‐heating chamber
‐Off gas flap of by pass system closed
KR Tec PROCESS STEPS OF EPC
Preheating inside EPC
‐Start feeding of preheated scrap after tapping
‐Pre‐heating chamber half empty hopper can move backward to waiting
position
KR Tec PROCESS STEPS OF EPC
Preheating inside EPC
‐Scrap bucket in waiting position
‐Continuous feeding of scrap during power on
‐Control of preheating scrap temperature with by‐pass regulation flap
KR Tec PROCESS STEPS OF EPC
‐Start feeding of preheated scrap
‐Opening of sliding gate on top
‐Charging of next bucket into charging hopper
KR Tec PROCESS STEPS OF EPC
600
LIQUID STEEL
500
SCRAP WEIGHT
400 IN FIRST
CHAMBER
200
SCRAP WEIGHT
IN SECOND
100 CHAMBER
-
0 5 10 15 20 25 30 37 42 47 52
LIQUID STEEL LEVEL
KR Tec DURING CYCLE WITH EPC
140
EAF
120 C A PA C I T Y
100 TON
100 TRANSFORME
R C A PA C I T Y
80
LIQUID STEEL
60
SCRAP WEIGHT IN
FIRST CHAMBER
40
SCRAP WEIGHT IN
SECOND
REPARATI
PREEPARATION
20 APPING CHAMBER
1 HEAT CYCLE
PR
TA
-
0 5 10 15 20 25 30 37 42 47 52
C O M PA R I S O N O F
KR Tec PRODUCTIVITY
PRODUCTION DIFFERENCE
EPC - EAF CONVENTIONAL EAF
Tra n s f o r m e r M VA 100 100
Ta p - w e i g h t t 100 100
Net working hours h/y 7.200 7.200
Power-on Time min 32 36
Power-off time min 6 11
Ta p - t o - Ta p - t i m e min 38 47
Production/hour t/h 157,89 127,66
Production/year t/y 1.136.842 919.149
Difference t/y 217.693
20 % PRODUCTIVITY INCREASE
WITH EPC SYSTEM
(100 TON – 100 MVA FURNACE)
C O M PA R I S O N O F
KR Tec O P E R AT I O N E L C O S T
O P E R AT I O N A L C O S T D I F F E R E N C E
CONVENTIONAL
Unit price EPC- EAF EAF
Consumptio Consumptio
Unit EUR n EUR/t n EUR/t
T O TA L 377,7 385,5
Savings EUR/t 7,8
8 €/T SAVING IN OPERATIONAL COST WITH EPC SYSTEM
(100 TON – 100 MVA FURNACE)
C O M PA R I S O N O F
KR Tec CONVERSION COSTS
AROUND 16 MILLION EUR ANNUAL SAVING
WITH EPC SYSTEM
WITH EPC SYSTEM
(100 TON – 100 MVA FURNACE)
KR Tec C O M PA R I S O N O F R I O
R O I C O M PA R I S O N
30
25
20
15
ROI FOR
Million Euro
10
EPC-EAF
EPC - EAF
5 CONV EAF
-
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-5
ROI FOR CONV-
EAF
-10
-15
Time (month)
EPC SYSTEM
KR Tec POWER FLUCTIONS
VOLTAGE, CURRENT AND POWER FLUCTUATIONS;
BEFORE AND AFTER SCRAP PREHEATING
KR Tec R E F E R E N C E S ‐ M E LT S H O P S
Capacity
Year of start‐
Year of start
Customer Country Location Product Production units
(tpy) up
NURSAN METALURJI A S
NURSAN METALURJI A.S. Turkey Iskenderun 700 000
700.000 Billets Complete Meltshop
Complete Meltshop 2006
Sections
Casting Nr. of
Nr of Year of
Year of
Customer Country Location Product
Radius Strands start‐up
(mm)
Square & round
YESILYURT DEMIR CELIK A.S. Turkey Samsun 8 m 6 100 ‐ 200 2007
billets
COJSCO Jordan
d Amman 6 m 3 Square billets
b ll 100 ‐ 160 2006
CER METAL A S
CER METAL A.S. Turkey Izmir 5m
5 m 3 Square billets
Square billets 200 2006
C
Customer C
Country Location
i Products
d
ARCELOR MITTAL ANNABA Algeria
g Annaba SMS 1 ‐ Moveable Hood & Fixed Hood
Ecological Solutions for
Electric Steel Making KR Tec