STEELMAKING TECHNOLOGIES AND NEW INNOVATIONS IN MELTSHOPS - CVS MAKINA

CVS Makina. Company Presentation

IntroductionIntroduction

• CVS provides turn-key plants and

equipment solutions for STEEL

SHOPS and ROLLING MILLS for

long products.

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

New developments in steelNew developments in steel

CVS has developed a new type of

project, i.e.:

ØThe super-flexible EAF base

Minimill concept

TheThe SSuperuper--FFlexiblelexible EAFEAF basebaseMMinimill Conceptinimill Concept

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

• All EAF’s were designed as rated 130 tcapacity equipped with the latesttechnologies in terms of metallurgical,mechanical, electrical and automation

Main Design ConceptMain Design Concept

• Nr. of scrap bucket charge : 2

• Tapping weight : 130 t

• TTT : 40 min.

• Tapping temp. : 1600-1620°C

• Hot heel amount : 20-40 t

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.

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

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 asDRI 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.

• Slag stability

• Control the slag foaming by controlling

slag composition

• High impedance application

• SIM-ARC electrode regulation design

Slag FoamingSlag Foaming

Other Features of E.A.F.Other Features of E.A.F.::

• Hot heel practice

• Control of liquid steel

• Chemical energy input

• Fast scrap charging

• New roof lifting mechanism design

• Scrap yard flexibility

New EAF Roof Lifting MechanismNew EAF Roof Lifting Mechanism

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

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.

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.

LADLE FURNACE (LF)LADLE FURNACE (LF)

• Optimum size• Essential part of the

secondary metallurgytreatment

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

LFLF DesignDesign AdvantagesAdvantages

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

• Electro-hydraulic electroderegulation

• Electrode arms with reducedelectrode pitch diameter

• Roof lifting mechanism viahydraulic cylinder

PERFORMANCES Plant A Plant B Plant C

Plant 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. (Nm³ /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

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 refractoryconsumption (kg/t)

2.5 - 2.6 2.1 - 2.3

Ladle life (heat) 90 - 92 80 - 95

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 (Ømm) 7,200 7,200 7,200

Lower shell (Ømm) 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 (m³) ≥155 ≥155 ≥155

Scrap bucket vol (m³) 146 130 140

Electrode (Ømm) 24” (610) 26” (660) 24” (610)

Max. Sec. Current (kA) 70 70 75

PCD (Ømm) 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

Company Plant A Plant B Plant C

Plant unit: L.F.Transformer (MVA) 20+20% 18+20% 20+20%

Max. SecondaryVoltage (V)

386 330 382

Max. SecondaryCurrent (kA)

37 40 40

Electrode (Ø, mm) 406 406 450

PCD (Ø, mm) 750 700 750

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

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

Company Plant A Plant B Plant CPlant 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 (m²) 22.000 30.385 22.300

Main fans (m³/h) 6 x 400.000 6 x 500.000 4 x 600.000

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

(m³/h) 2.400.000 3.000.000 2.400.000

Outlet dust content(mg/Nm³) ≤ 20 ≤ 20 ≤ 20

Company Plant A Plant B Plant CCCM 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 torch

Discharge 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.

ConclusionConclusionss

• In the last few years, CVS has supplied nr. 3 same sizeEAF’s.

• One of those projects was also a complete “turn-key”green-field project and it has been completed in 16months.

• The three EAF’s 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 practiseis giving significant advantages to investers in termsof their present and future’s plans.

Thank You For Your Patiencewww.cvs.com.tr