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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
CVS - VD/VODVacuum Technology in Secondary Metallurgy
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
CVS - VD/VODVacuum Technology in Secondary Metallurgy
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
CVS - VD/VODVacuum Technology in Secondary Metallurgy
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
CVS - VD/VODVacuum Technology in Secondary Metallurgy
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
CVS - VD/VODVacuum Technology in Secondary Metallurgy
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
CVS - VD/VODKey Features
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
CVS - VD/VODKey Features
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 - VD/VODKey Features
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
CVS - VD/VODKey Features
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
CVS - VD/VODKey Features
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
CVS - VD/VODKey Features
Level 1 Software
CVS - VD/VODKey Features
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
CVS - VD/VODKey Features
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
CVS - VD/VODKey Features
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
CVS - VD/VODKey Features
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
CVS - VD/VODKey Features
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
CVS - VD/VODKey Features
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
CVS - VD/VODKey Features
- Precise and fast off-gasanalysis- Better process controlthrough double-checking theprocess model results anderror correction mechanisms
CVS - VD/VODKey Features
- On-line steelchemistry analysis
- On-line slagchemistry analysis
- On-line steeltemperaturemeasurement
CVS - VD/VODKey Features