vd presentation cvs

CVS MAKINA - Company Presentation

Ø CVS provides plants & equipment for minimills,also in “turn-key” solution.

Ø CVS covers the complete design andmanufacturing activities for green-field projectsas well as revamping/upgrading of existingplants and equipment.

Ø CVS manufactures spare parts & componentsfor meltshops & rolling mills.

Ø CVS provides technical assistance andconsulting service to steel production.

Quick Info

CVS MAKINA - Company Presentation

Ø CVS headquarter is placed in the industrialregion of Gebze, just east of Istanbul, closeto many major ports

Ø Our modern facilities consists of more than40,000 sqm of closed area and a land ofadditional approx. 40,000 sqm

Ø CVS workforce is formed by over than 500specialized workers and engineers with amodern machinery park to undertake eventhe most challenging projects.

Ø Over than 200 engineers and administrativeemployees are involved in the design andmanagement of the projects.

CVS Makina. Company Presentation

VACUUM DEGASSING UNIT

From Steam Ejector Pump to Dry Mechanical Pump, from single tank to completeVacuum Degassing Unit and from Engineering Services to Turn-Key Plants, CVS offerseconomically viable solutions at European standards.

CVS - VD/VODDesign Concept

qCVS Provides VD/VOD units wit a joint venturecompany established in 2007

qTurn-key solutions provider forq Process Plants and Installations in Vacuum&Pressure

Applications

q SCADA Automation Projects

qDesign and Production Facilities forq Vacuum& Pressure Systems

q Automation and Software

qServices Provider for Energy Sector

CVS - EAFDesign Main Objective

q Dry Pump technology for Vacuum Systemq Integrated solution for Process and Plant Automation (level 1

+ 2 Automation)q Innovative Process Control: AI@SOLIS and AI@GASq Advanced Process Simulation and Optimizationq Substantial Energy Saving Solutionq Environmental Safe Solution

CVS - VD/VODDry Mechanical Pump versus Steam Ejectors

• Energy and Cost Saving• Higher Hydrogen Elimination and Better

Performances on working pressure• Clean and Environmental Friendly

Technology• No cleaning required• Full computer controll• Easier Maintenance• Fast turn on / turn off service

CVS - VD/VODEnergy and Cost Saving

Steam Ejector Spent Energy a typical VD 30 min. Degassingprocess:Average steam consume for a 800kg/h Steam Ejector: 16 t/h ofsteam16t/h x0.5h x 0.85Gcal/t = 6.4 GCal = 7.42 MWh (thermal)Electrical equivalent of thermal energy for power turbines 40%Electrical equivalent of thermal energy consumed by Steam Ejectoris therefore: 7.42 MWh x 0.40 = 2.97 MWh (electric)Energy for water pumping (800m3/h): 300 kWhTotal Steam Ejector Energy Consume 3.3 MWhMechanical Pump System consumed power:450kW x 0.5 h = 225KWhRatio of consumed power: 3.3MWh/0.225MWh=14.6 times

15 times less energy consume

CVS - VD/VODHigher Nitrogen and Hydrogen Elimination

qSievert Law:

2][ Heq pKH =where pH2 is partial pressure of H2 above liquid steel and K is a constant

• In case of a steam ejector pH2 is around 66% of total pressureat 1 mbar this means 0.66 mbar; therefore to performdegassing of the steel we need to go under this pressure

• In case of dry pumps pH2 is around 0.5% of total pressuretherefore the degassing process is more efficient and mostimportant can be done at higher pressure

• For a dry pumping system 10 mbar is a good degassingpressure

CVS - VD/VODClean and Environmental Friendly

• No water contamination• Dust concentration in

exhaust gas < 5mg/m3

• Global Steel IndustryRequirement ofReduced Green HouseEmission is fullyachieved by using DryPumping Technologyinstead of SteamEjectors

• Saving Energy Effect onReduced CarbonFootprint

Typical view of a Steam Ejector Pipe

CVS - VD/VODDry Pumping System Structure

3rd StageCompressor PumpWorking Pressure 1000-25 mbar

2nd StageRoots Type PumpWorking Pressure 25-5 mbar

1st StageRoots Type PumpsWorking Pressure 5-0.1 mbar

CVS - VD/VODScale of Evolution

Small ScalePilotPlant

Proving DPTat large scaleInstallations

High TechSolution

Turn KeySolutions

Very LargeCapacity VPS

1998 2001 2003 2007 2008

COST VOD 12 t

MMZ VD/VOD 100 t

AVMIN VIM 6T

TMK VD 100 t

Integrated SolutionProcess&PlantAutomation

CHONGQING RH 250 t

OUTOKUMPU VOD 2X 80t

2009

CVS - VD/VODVacuum Technology in Secondary Metallurgy

q First Application of DryPumping Technology inSteel Degassing &Processing (VOD)

q Patent RO118309q 12 t VODq Stainless Steel, Special

Turbines Steel andImplant Steel

VOD 12t, Romania, 1998


q VD/VOD 100 tq First Application of Dry Pumping

Technology at large DegassingPlants

q Low Carbon Steelq Stage 1: 14 x GV 400 Drystar

Pumpsq Stage 2: 3 x HV 14000 Dresser

Roots Blowersq Stage 3: 4 x HV 30000 Dresser

Roots Blowers

Stage 3

Stage 2

Stage 1

VD/VOD100t, Moldova, 2001


q Vacuum InductionMelting and CastingFurnace

q 6 t capacityq Application: Special

Steel for Space Industryq High Vacuum

Processing Technology:10-5 mbar

q Vacuum Pumps: Dry +Roots Blowers + VaporBoosters

A6t, South Africa, 2003


q VD 100 tq Turn-key deliveryq Application: Mechanical

Pipe Steelq Low hydrogen content in

25 min process timeq 3 stage vacuum system

based on skid technologyq 4 skids at a total of 150

kg/h @ 0.5 mbarq New design for vacuum

filter and filter controlsystem (<5 mg/m3 dustload at exhaust)

q Level 1.5 automation

TMVD 100t,Romania, 2007


q Largest Dry VacuumSystem for SteelProcessing

q RH 250 tq Innovative design for filter

systemq Application: Special Steelq Low hydrogen content in

15 min process timeq 76 pumps arranged in 19

skidsq 1000kg/h @ 1 mbar pump

capacityq Level 1.5 automation

RH 250 t, China, 2009


q Twin VOD 80 tq Process Simulation &

Controlq Level 2 Automationq High Temperature Filter for

VOD Processq On-line Chemical analysis

by AI@SOLISq Process Gas Analysis by

AI@GASq Optimized Process

Technologyq Application: ULC

Superferritic Stainless Steelq Ultralow Nitrogenq Ultralow Sulphur

2 x VOD 80 t, Finland, 2009

CVS - VD/VODKey Features

q Advanced Design based on theProcess Simulation CVS can sizeproperly the vacuum system,vacuum pipes, filter, tank/processchamber and the other processequipment using the processsimulation technique

q 3D ModelingAutoDesk® Inventor 2009/2010Package is Standard for Plant Designand Engineering

Compact Design


Process Mathematical Models

- deH

- deN

- deC

0 2 4 6 8 100.01

0.015

0.02

0.025

Time, mi

[S],

ppm- deS

- Temperature model


Mathematical Models Validation

0

1

2

3

4

5

6

0 1 2 3 4 5 6

Analyzed, ppm

Cal

cula

ted,

ppm

0

20

40

60

80

100

120

0 20 40 60 80 100 120

Analyzed, ppm

Cal

cula

ted,

ppm

0

100

200

300

400

0 100 200 300 400

Analyzed, ppm

Cal

cula

ted,

pp

m

• state of the art accuracy• advanced “auto-tuning” techniques for parameter optimization based on measureddata

Experimental vs Model


q CVS expertise extends to alltypes of Secondary MetallurgyVacuum Processes: VD, VOD,VT, RH, VIM

q AI has designed at least one ofeach during the 10 years ofactivity in SD

q The sizes of the installationsdelivered to industry by CVS’sProcess Engineering Divisionranges from 6t up to 230t.Standard Design for 12 t; 50t, 80t,100t.

Versatile Design


q Mechanical Pumping Technology for Steel Degassing has as a key issuefor reliable operation:

the filtration technology used to separate the dust fromthe flow stream

CVS has developed an efficient Filter System which brings operationalbenefits in regards with other suppliers

q The filter technology must respond at minimum three tasksq allow an almost perfect dust separation with a very small pressure dropq withstand the harsh conditions of the process without being damaged by

temperature and ignition of the dustq Automatic System for Integrity Filter Monitoring as the filter damage may

result in pumps destruction

Innovation – Filtration Equipment


The Filter System developedBy CVS’s engineers responds toall three key demands:

q Efficiency of 99% gas load is lessthan 5 mg/m3

q Pressure drop: 0.1-0.2 mbarpressure drop;

q Operational temperature range:(20 -1000)o C

Innovation – Filtration Equipment


Level 1 Software


Level 2 Automation System

Process design

Process simulation

Results estimation

Advanced process calculation

Process parameters estimation

Level 2 automated control of the entire plant

Industrial aware process control of the entire plant

Plant overview in either automatic or manual control

Automatic model reaction to manual intervention in process

control

Advanced reporting and troubleshooting


Hardware Architecture

Modules located and running on :

L2A

Prim

ary/

Pro

duct

ion

Serv

erL2

A Fa

ilsaf

e/Te

st S

erve

r

Database

L1Simulator OPC Server

L3Simulator

Troubleshooting

Historical Logs

Configuration

L2A Server

Best Practices

To L1 InterfaceServer

To L3 InterfaceServer

To HMITo CalculationServer

• modular architecture

• 99.9% guaranteed

availability

• low maintenance


Full Automatic Process Control

• the metallurgicalprocess is fullycontrolled by the level 2software

• the operator isprovided with “one-look”process status

• however, the operatorcan easily at anymoment take control byoverriding the level 2software


Process Design

• unlimited flexibility in process design

• “technological objects” approach

• once established a “best practice procedure” through simulations, costanalysis and hot tests, the software will automatically follow it


Offline Process Simulation

0.1

1

10

100

1000

0 5 10 15 20 25 30 35 40

time, min

vess

el p

ress

ure,

mba

r

presiune la rece mbarpresiune la cald mbar

0

1

2

3

4

5

6

7

8

0 5 10 15 20 25 30

time, min

Hydr

ogen

con

tent

in s

teel

, ppm

• great tool in process design

• through process mathematical modeling, the need of industrial tests is greatly reduced - thussignificantly reducing costs


New Analytical Tools

AI@GAS - Off Gas Analysis System

AI@SOLIS - In Situ Analysis of the Steel Chemical Composition

The Level 2 system can greatly benefit from the interface with theseadvanced analytical tools. The calculations are validated through avalidation engine, this greatly improving the mathematical modelsaccuracy


- Precise and fast off-gasanalysis- Better process controlthrough double-checking theprocess model results anderror correction mechanisms


- On-line steelchemistry analysis

- On-line slagchemistry analysis

- On-line steeltemperaturemeasurement

vd presentation cvs

Technology

vdvod vacuum

steam ejector

vacuumamp

degassing

secondary

total pressure

cvs makina

cvs