eaf_lfpresentation_09

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CVS Makina. Company Presentation


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IntroductionIntroduction

CVS provides turn-key plants and

equipment solutions for STEELSHOPS and ROLLING MILLS for

long products.


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Company highlightsCompany highlights

Location: Gebze (Istanbul), Turkey

Employees: 700 people (>200 engineers)

Turnover: 75,000,000.00 (year 2008)

Manufacturing area: 40.000 sqm

covered


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New developments in steelNew developments in steel

CVS has developed a new type of

project, i.e.:

The super-flexible EAF base

Minimill concept


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TheThe SSuperuper--FFlexiblelexible EAFEAF basebaseMMinimill Conceptinimill Concept

CVS has supplied the same category ofE.A.F. to three steel-plants

All EAFs were designed as rated 130 tcapacity equipped with the latest

technologies in terms of metallurgical,mechanical, electrical and automation


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Main Design ConceptMain Design Concept

Nr. of scrap bucket charge : 2

Tapping weight : 130 t

TTT : 40 min.

Tapping temp. : 1600-1620C

Hot heel amount : 20-40 t


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TapTap--ttoo--TTapap TimeTime CycleCycle

Charging : 3 min.

Tapping : 3 min.

Preparation : 4 min.(EBT filling, gunning, etc.)

Power - off Time : 10 min.

Power - on Time : 30 min.TTT : 40 min.


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Plant layout conceptsPlant layout concepts

TheThe plantplant layoutlayout is studied tois studied to obtain theobtain thebelowbelow results :results :

Adequate size of area occupied

Adequate number of personel required

Optimum productivity and limited cost

Future extension possibility


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EE..AA..FF. main features. main features

The main core of the steelmaking is EAF, thecomplexity is coming from various types andblends of scraps and scrap substitutes such as

DRI and HBI.

Additional chemical energy based on carbon,fuel and oxygen is used as substitute of electricpower.

Due to the dynamic process input energy shouldbe controlled carefully.


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Slag stability

Control the slag foaming by controlling

slag composition

High impedance application

SIM-ARC electrode regulation design


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Slag FoamingSlag Foaming


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New EAF Roof Lifting MechanismNew EAF Roof Lifting Mechanism


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CVSCVS-- E.A.FE.A.F.. ProjectsProjects


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CVSCVS--BurnerBurner DesignDesign ConceptConcept

The location and the direction of the burners are determined toreduce the cold spots effect generated by the three-phase arc ofthe furnace, thus obtaining an even and faster melting.


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CVSCVS-- BurnerBurner PositioningPositioning InsideInside FurnaceFurnace

The lance manipulator for the Electric Arc Furnace is primarily designed forsafe oxygen injection. Same manipulator is used for carbon injection aswell.

The Carbon injection in the bath have demonstrated of outmost importanceto work with proper foaming of the slag and to obtain recarburisation ofliquid steel bath if required to control bath composition.


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LADLE FURNACE (LF)LADLE FURNACE (LF)

Optimum size

Essential part of thesecondary metallurgytreatment


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LF AdvantagesLF Advantages

Saving of ferroalloy Saving of energy Increase productivity

Decreasing refining time of EAF Decreasing tapping temperature at EAF Precise temperature control Improved of inclusions, cleanliness of the

steel Possibilities of wrong analysis limited


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LFLF DesignDesign AdvantagesAdvantages

Water-cooled ladle roofequipped with indirect fumecollecting hood to reducesteel oxidation

Electro-hydraulic electroderegulation Electrode arms with reduced

electrode pitch diameter Roof lifting mechanism via

hydraulic cylinder


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PERFORMANCES Plant A Plant B Plant CPlant Unit: E.A.F.

Tapping weight (t) start-up 130/present 140 start-up100/present 135t start-up 130/present150

TTT (min.) 50-56 40-48 38-42 48-55 42-47 55-60

Productivity (t/h) 170 185 150 167 150-185

Electric consp.( kWh/t) 380-410 340-380 380-410 370-400 360-390

Electrode consp. (kg/t) 1.5-1.6 1.20-1.30 1.5-1.6 1.35-1.50 1.25-1.35

O2 consp. (Nm /t) 43 42 38 40 30-35

Carbon consp.(kg/t) 15 15-20 20 22 18-22

Refractory (kg/t) 4.20 3.60 3.67 3.35

Shell life (# of heat) 480 500 450 750

Roof delta life (heat) 520 560 450 700

Lime comp. (kg/t) 45-50 30-35 45 42 45-50

PRODUCTIONRECORD:

heat/day 32 33 37 29 25

t/day 4100 4440 3597 4013 3750


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PERFORMANCES Plant A Plant B Plant C

Plant unit: L.F.

Electric consumption

(kwh/t)

26 - 33 30 - 33 30 35

Electrode consumption

(kg/t)

0.26 - 0.31 0.31 - 0.32 0.35 - 0.40

Lime consumption

(kg/t)

11 14 6 - 8 8 - 10

Ladle refractory

consumption (kg/t)

2.5 - 2.6 2.1 - 2.3

Ladle life (heat) 90 - 92 80 - 95


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Company Plant A Plant B Plant C

Plant unit: E.A.F.

Furnace Type AC-EBT/Turret gantry AC-EBT/Turret gantry AC-EBT/Buggy gantry

Upper shell (mm) 7,200 7,200 7,200

Lower shell (mm) 7,400 7,400 7,400

Upper shell height (mm) 3,000 3,000 3,000

Serios reactor(MVAr) ON-LOAD 36 ON-LOAD 46 ON-LOAD

Transformer (MVA) 120+10% 135 130+20%

Max. Sec.Volt (V) 1,200 1305

Inner volume (m) 155 155 155

Scrap bucket vol (m) 146 130 140

Electrode (mm) 24 (610) 26 (660) 24 (610)

Max. Sec. Current (kA) 70 70 75

PCD (mm) 1300 1300 1300

Electrod arm Cu-cladded Cu-cladded Cu-cladded

Oxy/fuel burner+sup.Jet 5+1 EBT 5+1 EBT 4+1 EBT

SVC capacity (MVAr) 170 175 200


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Plant unit: L.F.

Transformer (MVA) 20+20% 18+20% 20+20%

Max. Secondary

Voltage (V)

386 330 382

Max. SecondaryCurrent (kA)

37 40 40

Electrode (, mm) 406 406 450

PCD (, mm) 750 700 750

Electrode arm type Cu-cladded Bus-tube Cu-cladded

Heating rate (C/min) Max. 5C/min 4.5C/min max. 5 C/min


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Plant unit: Fume Treatment Plant - FTP

Dedusting Plant: (Existing) (Existing, CVSSupply)

(New CVSSupply)

Emission type EAF primary & secondary + LF/MHS emissions

Filter Type Pulse-jet off-line Pulse-jet off-line Pulse-jet off-line

Filter surface (m) 22.000 30.385 22.300

Main fans (m/h) 6 x 400.000 6 x 500.000 4 x 600.000

Elect. Motors (KW) 6 x 800 6 x 1.400

Sucking capacity(m/h) 2.400.000 3.000.000 2.400.000

Outlet dust content(mg/Nm)

20 20 20


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CCM Existing Existing NEW (CVS supply)

Machine Type Curved mould Curved mould Curved mould 1 m.

Radius (m) 6 5 9/17

Number of strands 7 6 6

Cast section (mm) Square 100 - 150 Square 100 - 140 Square 130 200

Tundish capacity (t) 30 max. 28 max. 35 max.

Mould level control magnetic camera Co-60

M-EMS yes no Yes

Oscillating unit mechanical mechanical Hydraulic

Dummy bar rigid flexible Rigid

W/S 2 drives/std 2 drives/std 3 drives/std

Billet cutting oxy-gas torch Hydraulic shear oxy-gas torchDischarge system Liftable transfer Cross transfer Cross transfer

Billet transfer W.B. Cooling bed W.B. Cooling bed W.B. Cooling bed

Casting speed sp.140 mm 3.2 max sp.150 mm 2.8 max sp.150 mm 3.1 av.

sp.130 mm 4.1 av.


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ConclusionConclusionss

In the last few years, CVS has supplied nr. 3 same sizeEAFs.

One of those projects was also a complete turn-keygreen-field project and it has been completed in 16months.

The three EAFs are using in the range of 90t to 150tliquid steel without modifications. Since manyrestrictions at their beginning stage of start-up. 160t isexpected in the near future either with high bulkdensity scrap or with 3 charges.

These superflexible approach to steel making practise

is giving significant advantages to investers in termsof their present and futures plans.


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Thank You For Your Patiencewww.cvs.com.tr

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