Vd Presentation Cvs

VACUUM DEGASSING UNIT – VD/VOD

CVS MAKINA - Company Presentation

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

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

CVS manufactures spare parts & componentsfor meltshops & rolling mills.

CVS provides technical assistance andconsulting service to steel production.

Quick Info

CVS MAKINA - Company Presentation

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

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

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

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

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

Turn-key solutions provider forProcess Plants and Installations in Vacuum&PressureApplications

SCADA Automation Projects

Design and Production Facilities forVacuum& Pressure Systems

Automation and Software

Services Provider for Energy Sector

CVS - EAFDesign Main Objective

Dry Pump technology for Vacuum SystemIntegrated solution for Process and Plant Automation (level 1+ 2 Automation)Innovative Process Control: AI@SOLIS and AI@GASAdvanced Process Simulation and OptimizationSubstantial Energy Saving SolutionEnvironmental 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

Sievert Law:

2][ Heq pKHwhere 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

First Application of DryPumping Technology inSteel Degassing &Processing (VOD)Patent RO11830912 t VODStainless Steel, SpecialTurbines Steel andImplant Steel

VOD 12t, Romania, 1998


VD/VOD 100 tFirst Application of Dry PumpingTechnology at large DegassingPlantsLow Carbon SteelStage 1: 14 x GV 400 DrystarPumpsStage 2: 3 x HV 14000 DresserRoots BlowersStage 3: 4 x HV 30000 DresserRoots Blowers

Stage 3

Stage 2

Stage 1

VD/VOD100t, Moldova, 2001


Vacuum InductionMelting and CastingFurnace6 t capacityApplication: SpecialSteel for Space IndustryHigh VacuumProcessing Technology:10-5 mbarVacuum Pumps: Dry +Roots Blowers + VaporBoosters

A6t, South Africa, 2003


VD 100 tTurn-key deliveryApplication: MechanicalPipe SteelLow hydrogen content in25 min process time3 stage vacuum systembased on skid technology4 skids at a total of 150kg/h @ 0.5 mbarNew design for vacuumfilter and filter controlsystem (<5 mg/m3 dustload at exhaust)Level 1.5 automation

TMVD 100t,Romania, 2007


Largest Dry VacuumSystem for SteelProcessingRH 250 tInnovative design for filtersystemApplication: Special SteelLow hydrogen content in15 min process time76 pumps arranged in 19skids1000kg/h @ 1 mbar pumpcapacityLevel 1.5 automation

RH 250 t, China, 2009


Twin VOD 80 tProcess Simulation &ControlLevel 2 AutomationHigh Temperature Filter forVOD ProcessOn-line Chemical analysisby AI@SOLISProcess Gas Analysis byAI@GASOptimized ProcessTechnologyApplication: ULCSuperferritic Stainless SteelUltralow NitrogenUltralow Sulphur

2 x VOD 80 t, Finland, 2009

CVS - VD/VODKey Features

Advanced Design based on theProcess Simulation CVS can sizeproperly the vacuum system,vacuum pipes, filter, tank/processchamber and the other processequipment using the processsimulation technique3D 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


CVS expertise extends to alltypes of Secondary MetallurgyVacuum Processes: VD, VOD,VT, RH, VIMAI has designed at least one ofeach during the 10 years ofactivity in SDThe 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


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 suppliersThe filter technology must respond at minimum three tasks

allow an almost perfect dust separation with a very small pressure dropwithstand the harsh conditions of the process without being damaged bytemperature and ignition of the dustAutomatic System for Integrity Filter Monitoring as the filter damage mayresult in pumps destruction

Innovation – Filtration Equipment


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

Efficiency of 99% gas load is lessthan 5 mg/m3Pressure drop: 0.1-0.2 mbarpressure drop;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


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