Upload
andavilli-srihari-kumar
View
250
Download
0
Embed Size (px)
Citation preview
8/12/2019 EAF Basics Ppt
1/29
www.iac-intl.com
1
Industrial Accessories Company4800 Lamar Ave
Mission, Kansas 66202
Electric Arc Furnace
TechnologiesCorporate
Background
PP003
8/12/2019 EAF Basics Ppt
2/29
www.iac-intl.com
2
Regulatory RequirementsCoke Oven-Pushing Emissions New Mact Standards for Opacity (20% opacity during push).
Will require more efficient capture.
May require capture of "travel" emissions.
Blast Furnaces
May require retrofit from ESP &/or Venturi Scrubber to Baghouse
Primarily FF, however there are 2 VS installations.
PM control - 0.009 gr/dscfOpacity - 20% for existing plants; 15% for new plants.
Basic Oxygen Furnace (BOF) All US "Open or Closed Hood" designs have either an ESP or VS.
Primary Control BOPF w/Closed Hood - 0.024 gr/dscf
BOPF w/Open Hood - 0.019 gr/dscf
Secondary Control 0.01 gr/dscf for existing plants
0.0052 gr/dsf for new plants
Electric Arc Furnace (EAF) EAF Control Device: Lead Emissions of 0.0002 grains/DSF
EAF Control Device: Opacity of 3%
Melt Shop Building Roof Ventilators: Opacity of 6%EU developing new standards for EAF emissions for following:
* arsenic; cadmium; nickel; and Polyaromatic hydrocarbons (PAHs)
* Once standards get adopted, US market will also be affected.
Sinter Plants
Windbox Exhaust 0.3 lbs per ton of product sinter (old & new plants)
Discharge End 0.02 gr/dscf - existing plant; 0.01 gr/dscf - new plant
20% opacity for secondary emissions - existing plant
10% opacity for secondary emissions - new plant
Cooler stacks 0.03 gr/dscf - existing plant; 0.01 gr/dscf - new plant.
General Bag leak detection systems
Opacity Monitoring
Continuous parameter monitoring system
Record keeping
For Steel installations, the general accepted limit is 0.0052 gr/dscf
8/12/2019 EAF Basics Ppt
3/29
www.iac-intl.com
3
EAF Process Design
Bleed-In-Air Damper
Opposed Blade Dam per
Break Flange/Retractable Duct
Water Cooled/Refr actory Duct
Pressure Sensor
Fce Elbow
W/C or Refractory To Baghouse / ID Fans
(Suction or Pressur e Design)
Water Cooled/Refr actory Duct
Electric Arc Furnace
Combustion
ChamberQuench
Tow er
Canopy Hood
Louver Damper
8/12/2019 EAF Basics Ppt
4/29
www.iac-intl.com
4
EAF & Ladle FurnaceCanopy Hood
Louver Control Damper
Combustion Chamber
Electric Arc Furnace
Break Flange /
Retractable Duct
Bleed in Air Damper
Damper
Hot Quenching
Ladle Furnac e
Break Flange /
Retractable Duct
8/12/2019 EAF Basics Ppt
5/29
www.iac-intl.com
5
DEC / 4TH Hole Exhaust
8/12/2019 EAF Basics Ppt
6/29
www.iac-intl.com
6
Water Cooled Duct With W/C Damper
8/12/2019 EAF Basics Ppt
7/29
www.iac-intl.com
7
Side Draft Hood
Enclosure Box DesignE l e c t r o d e s
E L E C T R O D E C l a m p h o ld e r
F u r n a c e M a s t h o ld i n g t h e e le c t r o d e s
B r a c k e t s
F u r n a c e M a s t h o ld i n g t h e e le c t r od e s
H o o d w i t h t o p p l a te a n d o p e n b o t t om
A t th i s e n d , th e h o o d w i l l h a v e l o u v e r s , w h i c h c a n b e m a n u a l l y a d j u s t e d . T h i s w i ll a l l o w d i l u t i o n a ir to
e n t e r a n d t o d i v e r t th e f u m e s c o m in g o u t o f t h e e l e c tr o d e h o l e s .
E l e c t r o d e H o le O p e n i n g s ( 3 m i n . c l e a r a n c e f o r t h e e l e c tr o d e )
T h e a b o v e h o o d d e s i g n c a n b e i n s t a ll e d b e t w e e n t h e m a s t a n d t o c o ll e c t t h e e m i s s io n s t h a t e s c a p e b e t w e e nt h e a n n u l a r s p a c e b e t w e e n t h e e l e c t r o d e a n d t h e f u r n a c e r o o f h o l e s f o r t h e e l e c tr o d e s .
I n u s i n g t h i s d e s i g n , t h e fo l l o w i n g m u s t b e r e v ie w e d c a r e f u l l y :
1 . T h e m a s t h o l d i n g t h e e le c t ro d e s c a n o n l y b e lo w e r e d t o a p o i n t a b o v e t h e h o o d . T h i s w i l l l im i t t h e
m a s t m o v e m e n t . I n m o s t E A F s th i s i s a c c e p t a b l e.2 . T h e h o o d w i ll h a v e t o b e s tr e s s r e li e v e d a n d c o n s tr u c t e d o f S S 3 1 7 - L . I n o p e r a ti o n , th e h o o d w i ll
t a k e a n i n i ti a l w a r p a n d t h e n w i l l s ta b i l i z e .3 . T h e d u c t ta k e - o f f f ro m t h e h o o d w i ll h a v e a b r e a k f la n g e t o a c c o m m o d a t e th e r o o f s w i n g .
8/12/2019 EAF Basics Ppt
8/29
www.iac-intl.com
8
Side Draft Hood
Finger Hood Design
To Baghous e
Pivot Point for Roof
Bre ak Flange
Fur nace Roof Mast
Slag Door w ith Vent
Pour Spout
EXHAUST L OCATION
Ar ou nd Elect rod es
Slag Door
Tap Spout is plugged for the Melt Cycle
Des ign allow s fo r coolin g Air at Bre akflange . Exhaust t o Baghous e at 250 F.
8/12/2019 EAF Basics Ppt
9/29
www.iac-intl.com
9
Canopy Hood DesignDes ign 1830,000 ACFM
18'-0" Dia Duct
Louver Dam per Louver Dam per
9'-0" X 9'-0" 9'-0" X 9'-0"
Tapping Melting Slagging
8/12/2019 EAF Basics Ppt
10/29
www.iac-intl.com
10
Canopy Hood DesignDesig n 2
830,000 ACFM
18'-0" Dia Duct
Louver Dam per
9'-0" X 9'-0"
Tapping Melting Slagging
8/12/2019 EAF Basics Ppt
11/29
www.iac-intl.com
11
Canopy Hood DesignRELADLING OPERATION
CANOPY HOOD DESIGN
Low Profile Canopy Hood w/Two Discharge Ducts (each w/inner duct)
Side Discharge
B
HLP
A
X
Y
D
E C
No te : Ho od i s l oc ate d a bo ve Cr an e
Locate Hood as close as possible to the top of the ladle
Dimensions not provided, are assumed
Y 5.5 m 7 m
X 3 m 4.5 m
C 2 m 2.6 m
D 4 m 4 m
E 1.1 m 1.5 m
A 6.6 m 8.1 m
B 8 m 10.5 m
HLP 3 m 4 m
HTC 5.5 m 6.7 m
Low Profile Hood (acfm) 142,000 228,868
Low Profile Hood (am3/hr) 241,258 388,847
Tradition al Hood (acfm) 170,400 274,641
Traditional Canopy Design
Top Discharge
HTC
B
A
X
Y
C
8/12/2019 EAF Basics Ppt
12/29
www.iac-intl.com
12
IAC M PulseIAC "M" PULSE MODEL
Condition Flow Temp (F) IAC M-PULSE Baghouse
EAF 217,000 acfm 250 6 X 234TB-BHWT-360:S6
12 Penthouse w /Monorail
2
~ 6'-0"
Pneumatically Operated
Roof Door Outlet Poppet Dampers 14'-0"
One/Compt.
3'-6" Compt Outlet
23'-6"
9'-0"
Inlet Damper
Manual/Butterfly
Hd
2'-6" 60 Deg Side Angle
12"x12"
W To Suit
Grade
Baghouse Width
ELEVATION - TYPICAL SECTION THRU COMPARTMENT
Note: 1. Design of Inlet/Out let Plenum is prel iminary
2. The Header will be 12" Diameter (min).
3. Puls e Valves 2 1/2" min.
INLET PLENUM
(Tapered)
IP
h
IPw
OUTLET PLENUM
(TAPERED)
8/12/2019 EAF Basics Ppt
13/29
www.iac-intl.com
13
Side ElevationIAC " M" PULSE MODEL
Condi tion Flow Temp (F) IAC M-PULSE Baghouse
EAF 217,000 acfm 250 6 X 234TB-BHWT-360:S6
~ 6'-0"
14'-0"
3'-6"
3'-0"
OPh
23'-6"
IPh
A
CIh
6"
Hd
12" x 12"
Compt. Length
10'-0" Baghous e Length
Grade
CIw
Dirty Air Hous ing
Compt. Outlet
Compt. Inlet CIw
8/12/2019 EAF Basics Ppt
14/29
www.iac-intl.com
14
Velocity ProfileIAC "M" PULSE MODEL
Com pt length "L" Poppet Dam per
EAF Plenum Width
Flow: acfm 217,000
# of Compts. 6
Flow to One Compt. acfm 36,167
W ft 15.7
L ft 15.0
Inlet Damper-Height ft 3.5 Outlet Plenum Height
Inlet Damper-Width ft 6.89
Compt. Outlet - Height ft 2.5
Compt. Outlet - Width ft 8.0
Poppet Damper Size in. 48
Inlet/Outlet Plenum Width ft 10.5
Inlet/Outlet Plenum Height ft 5.9
VELOCITY PROFILE:
Inlet Plenum: fpm 3500 Inlet Plenum Height
A Across Inlet Damper fpm 1500B 40% Flow to Hopper fpm 386
C 60% Flow to Casing fpm 579
D In to Upper Casing fpm 132
E From Hopper fpm 73
F Exit from Compt fpm 1800
G Across Poppet fpm 2878
H Outlet Plenum: fpm 3500
Inlet Damper
2'-6"
Compt w idth "W"
INLET PL ENUM
F
D
C
B
E
OUTLET PL ENUM H
G
A
8/12/2019 EAF Basics Ppt
15/29
www.iac-intl.com
15
Tube-sheet DesignIAC "M" PULSE MODEL
W
14" 8"
8"
11" (typ )
8"
Row s
L
Inlet Flow
Bags /Blow Pipe 2'-6"
NOTE: Tube sheet d imens ions are approximate . Inte rnal s ti f fne rs fo r common wal l cons t ruc ti on may ex tend w id th.
PROJECT EAF
BAGS/COMPT 360
# ROWS 20
BAGS/BLOWPIPE 18
W (FT) 15.67
L (FT) 15.00
8/12/2019 EAF Basics Ppt
16/29
www.iac-intl.com
16
Plan View - One Door/HeaderIAC "M" PULSE MODEL
Condition Flow F IAC M-PULSE Baghouse
EAF 217,000 acfm 250 6 X 234TB-BHWT-360:S6
Inlet Outlet
Baghous e Width (Bw)
Baghouse Length (Bl)
EAF
# Compartments 6
Flow: acfm 217,000
Compartment Width ft 15.67
Compartment Length ft 15.00
Baghouse Width ft 41.8
Baghouse Length ft 45.0
8/12/2019 EAF Basics Ppt
17/29
www.iac-intl.com
17
M - Pulse Baghouse
Header Design Arrangement
90 Degree; Thr eaded, Double Diaphram Valve
3" Valve (Typical)
Header
Typ. 3" Blow-Pipe
Roof Top Door (6" High)
Outlet
8"
Typ . 3" Blow-Pipe (3 1/4" OD) 2" Over lap
Nozzle 2" 6"
(1 1/4" Sch 40)
3/16" Plate Tube s heet
Tube Sheet Hole: 6 1/4"
Bag & Cage:
6" Diameter
Cage: 5 3/4" Dia.
Inner Strike Plate
Bag to w all clearance is 3" (min)
Inlet Flow
8/12/2019 EAF Basics Ppt
18/29
www.iac-intl.com
18
M - Pulse Baghouse90 Degree Threaded Double Diaphragm Valve
8/12/2019 EAF Basics Ppt
19/29
www.iac-intl.com
19
M - Pulse BaghouseFull Immersion Design Header
Tank has integrated diaphragm valvescontrolled by remote solenoid pilots
8/12/2019 EAF Basics Ppt
20/29
www.iac-intl.com
20
Heat Exchanger
1.
Forced Cooling Fan, which blows cooling air in to the inside of the coolingtubes/pipes and the process gas is on the outside of the tube. The tubes/pipes are
located horizontally.
2. The hot process exhaust gases are vented to the Air to Air Heat Exchanger where they
pass through vertical parallel tubes. Cooling is accomplished by forced convectioninduced by cross-flow fans moving ambient air over the outside of the tubes.
8/12/2019 EAF Basics Ppt
21/29
www.iac-intl.com
21
Evaporative Cooling
Hot Gas Inlet Flow
Platform for access to nozzles
Acces s Lad de r
Evaporative Cooler
Cooled Gas Outlet Flow
To suit
Grade
8/12/2019 EAF Basics Ppt
22/29
www.iac-intl.com22
Lance / Nozzle DesignLance Assembly is constructed in 316 SS
8" 150lb. Flange s tandard (1" / 25.4 mm thick)
13.5" OD (342.9 m m)
11.75" 298.5 mm ) Diamet er bolt hole cente r
7.5" 190.5 mm Distance to suit Cooler Size
Liquid Inlet
1" NPT or BSPT
8.23" (209.1 m m)
2 1/2" sch 40 p ipe 2.75" (69.9 mm Hex
4" 2.875" OD
Nozzle Tip has 8 holes (fr ee pass age)
Air Inle t
1" NPT or BSPT
Nozzle Tip ConfigurationSpray Velocity designed in the range of 80 to 125 ft/sec (24.5 to 38.2 m/s)
0.188" (4.7 m m) to 0.393" (9.9 mm )
8 Holes
2.38" (60.3 mm ) to 2.75" (69.9 mm )
8/12/2019 EAF Basics Ppt
23/29
www.iac-intl.com23
Nozzle Dispersion
48"/1.22M
v y
Spr ay Velocity
"z"
A d iam et er
B Diame te r
NOZZLE PERFORMANCE REQUIREMENT
US UNITS METRIC UNITS
Atomizing Air Pressure: 20 / 40 / 60 / 70 / 80 psi 1.38 / 2.76 / 4.14 / 4.83 / 5.52 bar
Liquid Pressure: 13.9 to 95.5 psi 0.96 to 6.59 bar
Liquid Capacity: 0.5 to 30 gpm 1.89 to 113.56 l/min
NOZZLE DISPERSION ANALYSIS:
1 Spray Dimensions (y; and z)
2 Spray Velocity (v)
3 Spray Cloud Diamete r (A & B)
8/12/2019 EAF Basics Ppt
24/29
www.iac-intl.com24
Radiant Cooling
Radiant Tubes
(Height to suit)
Expans ion Joint
Screw Conveyor Rotary Valve
Grade
8/12/2019 EAF Basics Ppt
25/29
www.iac-intl.com25
Double Dump Valve Technology
Pneumatic Conveying
8/12/2019 EAF Basics Ppt
26/29
www.iac-intl.com26
Standard Products Pneumatic Conveying
Mechanical Conveying
Air Supply Equipment Valves/Flow Control
Bulk Storage
Baghouses
8/12/2019 EAF Basics Ppt
27/29
www.iac-intl.com27
Services Engineering Evaluations
System Design/Specification
Field Evaluation
Troubleshooting
Installation & Start-up
Maintenance
Scheduled/Preventive/Emergency
Bag Change-outs
Equipment Upgrades/Optimization
Turnkey Projects
Training - Operation/Maintenance
8/12/2019 EAF Basics Ppt
28/29
www.iac-intl.com28
IAC Key ReferencesRepresentative Reverse Air References Iron & Steel Industry:
1. Krupp Industrie GER 1,765,000 ACFM EAF
2. Hadeed Ltd. SAU 1,059,000 ACFM EAF
3. Gret Lakes Steel USA 1,231,000 ACFM EAF
4. Ferrowohlen SWI 765,000 ACFM EAF
5. Crucible Steel USA 865,000 ACFM EAF6. CF&I USA 540,000 ACFM EAF
7. Cascade Steel USA 486,000 ACFM EAF
8. Bethlehem Steel USA 874,000 ACFM EAF
9. Nucor, Kankakee USA 450,000 ACFM EAF
10. Kaiser Steel USA 600,000 ACFM Reladling
11. Wheeling Pittsburgh USA 180,000 ACFM Reladling
Representative References Boilers and Dry FGD:
1. C&H Combustiion USA 465,000 ACFM FBC/Incineration
2. Ormet Aluminium USA Pot Line Dry Scrubber
3. Reynolds Metal USA 141,000 ACFM Anode Bake Fce
4. Intalco Aluminium USA 168,000 ACFM Anode Bake Fce
5. ICM, Nevada, IA USA 165,000 ACFM Coal Fired Boiler6. ICM, Goldfield, IA USA 165,000 ACFM Coal Fired Boiler
7. Cemex, Fairborn, OH USA 65,000 ACFM Alkali By-Pass
8/12/2019 EAF Basics Ppt
29/29
www.iac-intl.com29
Contact Information
Corporate Address: 4800 Lamar Avenue
Mission, Kansas 66202
Corp Tel: (913) 384.5511 E-Mail: [email protected]
Sales Tel: (800) 334.7431
Corp Fax: (913) 384.6577
Knoxville Contact: Pramodh Nijhawan
318 Saint Andrews Drive
Knoxville, TN. 37922
Tel: (865) 675-7867 E-Mail: [email protected]
Fax:(865) 675-7582