Metals Technologies
Dedusting Solutions
Technology, mechanical engineering, automation and
electrical engineering from a single source – cleaner steel
production at attractive cost
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For every metric ton of steel produced, 10 to 25 kilograms of dust accumulate.
There‘s no question that modern dedusting systems are crucial, but the costs and
outlay for their operation should be no higher than absolutely necessary. The most
important goals are high reliability, strict compliance with prescribed threshold
values and reasonable energy consumption.
You expect …
Cost-efficient production and maximized productivity
Low consumption levels and efficient energy use
Short delivery times and consistently high availability
Flexibility of charge materials, and in the grades of steel produced
Solid production quality and highly expert solutions – “German quality standards“
Preparation for future environmental and market requirements
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The challenge:
Environmentally oriented
production – with an eye
toward the future
Cleaning up processes
The dedusting system should run cleanly,
removing the large amount of residue
from electric arc furnaces, ladle furnaces, vacuum furnaces or sintering furnaces. And it should run without being disrupted by unfavorable factors and events, such as the use of unclean scrap in steel pro-duction.
Decrease costs, increase availability
To achieve high reliability and favorable operating costs requires the right design. The more cleanly the process parameters are adapted to one another and the more precisely the design is tailored to the up-stream aggregate, the more smoothly the operation will run.
Maintenance is another cost aspect to consider. Long-lasting, low-maintenance components virtually eliminate unplan-ned downtimes. And planunplan-ned downtimes for the dedusting system should be coordi-nated with those of the plant as a whole
to keep total production as high as possible.
Is the system ready for the future?
A dedusting system requires sensible investments. That is why it is so important for the system to be able to accommo-date future expansions of production and potentially stricter environmental regulations – without requiring signifi-cant modification and conversion costs. And for the same reason, you need a plant layout that also offers flexibility for the future.
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Smooth operation – fully automated
Your automation solution reflects years of process knowledge. IT ensures flexible, secure operation, a high degree of safety for people and machinery and high ef-ficiency over the entire life-cycle of the system.
Advanced solutions, such as an inverter for large drives, contribute to decreased energy costs by allowing output and energy consumption to be continuously adapted to production demands.
Equipped for future demands today
Siemens VAI designs your system to harmoniously accommodate any future expansions with no long downtimes or start-up problems. Thus, with your initial investment, we’ve put you on the right track to effectively limiting subsequent costs later on.
The right approach:
Dedusting solutions for your
electric furnace steel mill
Years of expertise
Armed with proven concepts, which have been optimized over many years, we can master any challenge in the dedusting of your electric furnace steel mill. Our range of expertise encompasses five types of primary coolers alone.
Dependability comes from experience
The roughly 200 reference plants built in the last ten years stand as proof of our solid experience. Our engineers have definitively advanced important develop-ments, such as the quenching tower, and have brought them into series production.
You benefit from these advances through high availability, high reliability and guar-anteed elimination of residues such as di-oxin from an electric arc furnace. In other words, you produce steel while we make sure your systems – and thus your steel mill environment – stay clean.
Maintenance? Short, planned and efficient
Robust components, high-quality work-manship and the right design help keep maintenance to a minimum. And our intelligent maintenance time schedule proactively prevents any potential break-downs.
Our systems also allow bags to be changed during operation – another way we contribute to high availability.
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Siemens VAI now offers the entire spectrum of dedusting technology from a single
source, always in close collaboration with your company‘s steel production plant
specialists. This is our approach for creating perfectly coordinated, economically
viable solutions. Today, we combine the special expertise of what was known until
2005 as VAI Pomini with the resources and staying power of Siemens, ensuring
reliable implementation of even the largest projects.
Good reasons for our
dedusting solutions
Guaranteed compliance with agreed-upon limit values
Tailored dedusting units using compre-hensive mini-mill expertise
Future emission requirements are al-ready taken into account in the plant layout
Problem-free operation with low ser-vice requirements
Turnkey solutions from a single source – with one contact, and one person in charge
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To ensure reliable and low-maintenance
dedusting, all modules and processes
must be perfectly coordinated, including
with respect to EAF specifications and
secondary metallurgy. The focus here
is on monitoring the off-gases, their
composition and temperature. The
easi-est way to achieve this is with a solution
from a single source.
Clean solutions –
on every level
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Automation
With SIMATIC, Siemens has been setting the de facto standard in automation technology for about 20 years. No other system is so widely used in the metals industry. The concept of Totally Integrated Automa-tion supports a homogeneous automaAutoma-tion landscape that’s also a safe long-term investment, from the factory floor to the management level.
Total engineering
Accurate planning that addresses everything from energy supply and raw materials logistics to through-put targets is a prerequisite for a successful start of your plant. We provide all the up-front necessities to make sure your project gets off to a safe start, including technical consulting, financing, as well as simulation of all processes.
Life-cycle services
High availability calls for a well-designed service concept, up to and including around-the-clock moni-toring of the plant at Siemens headquarters. Clearly defined processes, uniform manuals, assured parts availability and a globally available team of special-ists ensure minimized shutdown times and high per-formance throughout the life-cycle of the plant.
Across all processes:
Electrical engineering, automation, expertise
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Material handling Ladle furnace Maintenance suction equipment Booster fan Spark (axial hor Canopy Sleeve
fi xed elbow Drop output box
Water-cooled hot gas line
Forced draught cooler (tube type)
Forced draught cooler (plate type)
Quenching tower (spraynozzle type) Spark (axial ve
Auxiliary dedusting
Secondary dedusting
Primary dedusting
Auxiliary dedustingAdditional off-gases from other areas are extracted using the auxiliary dedusting.
Primary dedusting
The off-gases of the electric arc furnace are extracted and cleaned with primary dedusting. Important here is the regulated cooling of the gases to avoid the ac-cumulation or formation of dioxins.
Secondary dedusting
The secondary dedusting takes the off-gases from the furnace covering.
Water-cooled hot gas line
Water-cooled lines cool down the off-gases to about 600 °C and therefore simultaneously reduce its volume.
The products – proven worldwide
and seamlessly integrated
Forced draught cooler
Forced draught coolers are an interesting alternative to the quenching tower, if dioxin does not play a pro-cess-specifi c role and noise protection is in the fore-front instead.
Ausklappseite 2 mm kürzer
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ter n Spark arrestor (axial cyclone) horizontal raught be type) raught te type) g tower zle type) Spark arrestor (axial cyclone)
vertical Mixing dust Fan Reverse air fi lter
Dust silo
Pulse jet fi lter ID fan and stack
Spark arrestor
Spark arrestors are upstream from the actual fi lter section. They protect the fi lter sacks from smoldering particles and simultaneously prevent the danger of explosion.
Quenching tower
The design of the tower signifi cantly determines the chemical composition of the dust. Siemens VAI sets up a two-stage cooling and thus can reliably stop the formation of dioxin. There are different types of cool-ers available depending on the requirements.
Filter
Various fi lter systems are available for selection, depending upon exhaust air specifi cation.
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Quenching towers
The greatest challenge is the fast cooling of the EAF vapor. Here it is important to stay below the temperature range of 200 to 400 °C; otherwise there is the risk that dioxins will form (de novo synthesis). To reliably prevent this, Siemens VAI quenching towers are equipped with the DECOS dioxin reduction system. Us-ing special jets, a water/compressed-air mixture is blown into the cooling tower. Depending on the current conditions, the measured water quantity leads to drip formation, which quickly cools down the off-gas flow.
In a second step, off-gas from the sec-ondary dedusting is mixed in, so that the temperature of the gas mixture goes even lower.
Advantages
Compared to conventional hairpin cool-ers, our quenching tower is distinguished by a number of concrete advantages. Inlet temperature can be up to 1,000° C, compared to the hairpin cooler which is only designed for temperatures up to 600 °C. Space requirements for water precooling are correspondingly smaller with our solution.
In addition, the pressure drop in primary dedusting is significantly smaller, thereby reducing energy consumption of the fans.
And finally, the quenching tower can be quickly and easily cleaned thanks to the simple accessibility of the unit. In con-trast, the lines in hairpin coolers tend to clog and need regular, time-consuming maintenance.
Quenching tower components
Settling chamber
Cylindrical body
Spraying lances installed in the lower part of the cylindrical body
Conical part in the cylindrical body top
Safety explosion doors
Connection duct between the quench-ing tower and the secondary fume line
DEC damper situated in the outlet duct
The cooling of the primary off-gas extracted from the electric arc furnace (EAF) can be done using different systems, which generally consist of the forced draught cooler (FDC) and the quenching tower (QT). When choosing the most suitable system, a major role is played by the necessity to limit the volumes of dioxin and furan emissions.
Primary off-gas cooling
Reliable and efficient
Quenching towers Quenching tower at EGE Celik, Turkey
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Forced draught cooler (FDC)
If the formation of process-specific di-oxins can be excluded, a forced draught cooler is an interesting alternative to the quenching tower (QT). Here the off-gases are extracted through individual lines and cooled from outside by fresh-air fans. Depending on the type of lines, plate- or tube-type coolers are available. Especially the latter type features a high heat trans-fer coefficient.
The cooler has cooling pocket sections with externally situated cooling air fans. Due to its pocket design, the cooler has a limited cleaning requirement, which ensures high levels of operational avail-ability.
Forced draught cooler components
Cooler designed with modular con-struction
Fans controlled according to cooling need
Low noise levels through optional silencers
Inspection doors in the upper part of the cooler
Hoppers to collect coarse dust
Inspection door on the hopper’s lateral side
On/off dampers
Forced draught cooler at ALZ, Belgium Plate-type cooling elements Hairpin natural cooler
Hairpin natural cooler
As an alternative to electrical fan (forced draught cooler – FDC) or air/water control (quenching tower – QT), a hairpin natural cooler can be installed.
Inlet header
Hoppers for dust transport
Inspection doors Pipe bundles No electrical consumption Lowest maintenance 11 070536_PP_Dedusting_RZ2.indd Abs2:11
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The environmental plants
installed by Siemens VAI comprise:
Pulse jet bag filter units and reverse air bag houses
EAF dedusting comprised of water-cooled ducts, drop-out boxes, quench-ing towers, forced draught coolers, cyclones, canopy hoods, mixing cham-bers, filters, fans and stacks
AOD dedusting comprised of water-cooled stacks, forced draught coolers, canopy hoods, filters, fans and stacks
Noise reduction, dog and elephant houses
DeS dedusting comprised of moveable hoods, cyclones, filters, fans and stacks
Dedusting systems for the glass and ceramic industry
As a state-of-the-art system integrator for EAF dedusting equipment, Siemens VAI offers comprehensive in-house solutions for primary and secondary off-gas treat-ment in the field of EAF steelmaking.
These proven Siemens VAI dedusting solutions are characterized by:
Advanced simulation tools
Modular design pulse jet filters
Proven water-cooled duct design
Proven quenching tower design
Proven forced draught cooler design
Custom-made solutions
“Fit-for-use” applications
Highest flexibility
Pulse jet bag filters
Clean solutions for dust handling
Carinox, Belgium, 2005 Venturi valve hall
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Our bag filters are characterized by:
Standard filters designed for low and easy maintenance in a steel shop envi-ronment
Modular filter design, which permits future extensions with add-on com-ponents
Dramatic reductions in installation times due to the modular design of prefabricated panels, hoppers and filter heads
Accurate blowpipe positioning with centering on the venturis, which en-sures long bag life
CFD-modelled filter casing for heavy particle separation and optimized flow distribution through bags
Low energy consumption due to the cast-aluminum classic venturi situated on top of the bags, which provide an efficient secondary air in-draught
Low energy consumption using straight blowpipes, which eliminates elbow losses
Low energy consumption and pressure loss through the filter casing, due to an optimized gas flow, large venturi diameters and maximized damper dimensions
Fully automatic filter cleaning with no moving parts on the inside of the filter
Filter cleaning operation in either online or offline mode
Filter cages, which are designed to protect the bags and allow them to be walked on after installation
Fully standardized service interchange-able parts, which are commercially available worldwide for the entire filter range
Hoppers with steep inclination avoid dust deposits. Pulse jet valve arrangement with noise cover
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Tasks of a computational fluid dynamics (CFD) simulation:
Minimization of the fumes in the melt shop
Optimized canopy design
Optimization of the maximum off-gas flow during scrap charging based on stationary simulated energy balance and fluid dynamics
CFD-simulated off-gas and tempera-ture distribution in dust hopper
Flow optimization with modern CFD
Flow distribution is optimized resulting in less wear and higher efficiency
The secondary dedusting line absorbs the emissions coming from the canopy hoods situated above the furnace. The correct sizing of a canopy hood is based on geometry and fluid mechanics. For this reason, control of secondary canopy hood sizes is increasingly per-formed using fluid dynamic computer simulation programs (CFD).
Secondary off-gas treatment
Precisely calculated flow control
Flow optimization with CFD (Computational fluid dynamics)
Efficient and optimized
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A doghouse/elephant house is a complete enclosure that isolates the furnace shell and evacuates the emissions generated during steel production processes. These furnace enclosures are characterized by:
Soundproof/sound-absorbent panelling
Weights varying from 100 to 160 kg/m2
Thicknesses of up to 350 mm
Guarantees of up to 85 dB (A) or lower
Strong inside ventilation during the tapping phase
Safety panels for explosion control
Complete or partial enclosure
Inlet air ventilation, supplied through silencers, which prevents fume stagnation
Heavy-duty design structures and gear motors with a high safety coefficient
High-speed door movement
Double sealing between mobile and fixed walls
Self-supporting design of the doghouse
Doghouse and elephant house
Minimizing noise emissions
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ERP MES Automation Power, drives and infrastructure
Process
Features
Siemens VAI automation (dedusting PLC) is integrated into an overall PLC system and is programmed according to cus-tomer needs. PLC-based programming allows energy-efficient bag cleaning us-ing different modes (Delta P, continuous, dynamic cleaning pattern) and enables a diagnosis of the bag status.
Benefits and applications
Our filter plants are operated with either online or offline cleaning using the Delta P, continuous and dynamic mode:
Continuous cleaning mode
Constant cleaning air pulses according to programmed values
Constant cleaning operation for shut-downs and maintenance operations
Siemens VAI stands for the combina-tion of technological expertise and unique automation experience in the metals industry.
We also support you in dedusting with advanced automation solutions that al-low you to completely focus on your core task – the production of steel.
Electrical and automation solutions
Enhancing the performance of your dedusting plant
Leading automation solutions based on standards such as SIMATIC S7 and SIMATIC IT …
… on all plant levels from the field up to the management level
Dynamic cleaning mode
Cleaning air pulses according to the differential pressure over filter, while the gas flow is also taken into account
Cleaning operation only when needed
Energy savings
Avoidance of mechanical stress
Cleaning operation for varying gas flows
Delta P cleaning mode
Cleaning air pulses according to the differential pressure over filter
Cleaning operation only when needed
Energy savings
Avoidance of mechanical stress
Cleaning operation for relatively constant gas flows
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You want your plant to produce at competitive costs over
its entire life-cycle, and always have state-of-the-art
tech-nology. That‘s why you make an investment. And for this
investment, you should expect an effective life-cycle
con-cept from your plant manufacturer.
Services offered by Siemens VAI range from planning, consulting and engi-neering to supply of both individual components and complete production line, including safe and rapid start-up. Whether we’re constructing new plants or modernizing existing capacities, our own training specialists make sure that your personnel know how to handle the process and technology safely and efficiently.
What we offer includes …
Presales studies – from design, engi-neering and feasibility studies to im-provement studies
Start-up support – from on-site training to accelerated start-up programs.
Spare part and component supply
Our spare parts service specializes in the engineering and supply of spare and wear parts, technological components and systems. Professional handling en-sures that you receive the right part in the shortest time possible.
Features
Dedicated spare parts service from small proprietary items to major assemblies
Stock control and distribution database Standard packages with measurable
client benefits
Dynamic spare parts and material management system
Material information system Substitution of parts including
reengineering
Service for electrical equipment and automation
The maintenance of your production fa-cilities and equipment is a significant cost factor for you. Yet unplanned process downtime greatly affects the earnings of the entire company. Risks must be mini-mized, as must the costs for keeping those risks small.
Our services
Best performance throughout your plant‘s lifetime
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Siemens VAI Life-cycle Services
As a plant operator, you have conflicting needs. On the one hand, your perfor-mance is measured each quarter against short-term profitability expectations. On the other hand, you have to think on a totally different timescale compared with the capital market. Depending on the lifetime of your plant, you have to take 15 years or more into account. At the very least, that’s 60 full quarters.
But thanks to our comprehensive exper-tise and integrated approach to solutions, you benefit both short-term and long-term from our life-cycle services. In the short term: Backed by our exten-sive experience with many reference plants, we provide you with the certainty of fast, dependable production start-up and shorter amortization periods. In the long term: Our master plan guar-antees competitive performance for your plant in every phase of its life-cycle. Whether we’re providing 24/7 techni-cal support, optimizing maintenance or making permanent plant improvements, we’re always working to ensure the cost-effective operation of your plant.
Recycling Moderniza
tion Newinve
stment Operation
• Investigation/inspections & feasibility study • Design
• Layout • Construction • Installation • Commissioning
Consulting | Planning | Financing
• Service contracts
• Spare parts and components • Consulting and training • Online and offline
maintenance • Maintenance contracting • Migration packages • Upgrading and modernization
Life-cycle management
Partnership never ends
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Turnkey solutions
Success from a single source
Instead of coordination effort …
Normally when a project is assigned there are a large number of suppliers to coordinate for timing, technology and logistics. This complexity is a major factor extending through the life-cycle of the plant, and raises a number of questions: Who is responsible if the design capacity is not achieved at the planned time? Who ensures that the system can be expanded with all its technical complexity?
… we offer a solution as prime contrac-tor that eliminates these worries:
We sort out the technical interfaces and incorporate all components harmo-niously into the overall concept. We work in partnership with
subcon-tractors, such as local companies, and guarantee overall quality.
We ensure completion on schedule and smooth start-up, so you can pay off debt on schedule.
We create a system that is optimized throughout to keep pace with growing requirements.
We construct your plant for a fixed price.
Numerous requirements must be fulfilled when building or modernizing
a dedusting plant. These include: Guaranteed completion within the
agreed time and cost framework, reliable start-up, and rapid attainment
of the planned production volumes and product qualities. The best way
to ensure meeting these requirements is with a turnkey solution from
Siemens VAI. We take complete responsibility for project implementation
and start-up of production, so you can concentrate on your core business
of manufacturing steel and marketing it profitably.
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Secondary processes are no minor matter
We provide our own Siemens solutions for nearly all processes associated with production, from the power supply to water treatment, and from fire protection to railway siding. And everything is backed by services from our local partners. This comprehensive approach is unique. Cross-functional concepts such as Totally Integrated Automation and Totally Inte-grated Power provide synergies and a high degree of standardization.
Your security: Our financial strength and project expertise
In a turnkey project you profit from quali-ties for which Siemens is famous world-wide. This includes a sound financial base as well as the ability to plan projects with foresight and to implement them reliably. It also includes many years of experience in complying with all rules and regula-tions, from customs regulations to ap-proval conditions.
And last but not least, it includes the enthusiasm of our engineers, fitters and start-up engineers, all eager to work together with you to create a world-class system.
If you’re planning to invest in a electric steel plant, we can provide the compre-hensive product, system, integration and service expertise you need for success.
We‘ll be glad to advise you.
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Excellence from experience
The zero-fume solution Customer: Carinox, Belgium
Plant type: Dedusting for EAF, doghouse EAF and converter AOD
Our solution: We installed two different filter plants, one with 28 compartments and one with 24.
The result: As demonstrated during EAF/AOD tapping and charging, the system operates effectively and at high capacity, with no fumes present in the bay.
Selected success stories with dedusting plants
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Cleaner air even under harsh conditions Customer: Terni, Italy
Plant type: Primary and secondary dedusting plant for AOD2 and AOD3
Our solution: We set up two new filters, one with 18 and one with 20 compartments.
The result: Using secondary fume suction lines, dust levels have been drastically reduced in the worst operation phases.
Hot? Everything under control Customer: Gerdau Group, Chile
Plant type: Upgrading of steel plant fume exhaust system for 60-t EAF
Our solution: We installed a new quenching tower and spark arrestor for the primary line in the existing plant after increasing the power of the EAF.
The result: The new quenching tower allows greater control at temperature peaks.
Dedusting solutions from Siemens VAI comprise many years of experience in plant construction embodied by VAI Pomini until 2005.
The integration of Voestalpine Industrieanlagenbau GmbH – and therefore of VAI Pomini – into Siemens AG placed our expertise in complete systems on a new basis. The success stories presented below provide just a brief impression of our comprehensive experience.
Reducing dust by 70% Customer: Arconi, Slovenia
Plant type: Upgrading of steel plant fume exhaust system for 85-t EAF + LF
Our solution: We implemented a 10-compartment filter for this system.
The result: Stack emission is now 1.2 mg/m3, with a noise level under Leq 48 dB (A)
at 100 m. Dust levels in the upper area of the steelshop have been reduced by 70%.
Quiet but powerful Customer: ALZ, Belgium
Plant type: Secondary dedusting plant for 120-t EAF
Our solution: We set up a new doghouse for the dedusting plant.
The result: Noise levels have been reduced to below Leq 85 dB (A).
Staying cool in every situation Customer: Gerdau Group, Canada
Plant type: Revamping of dedusting plant for one 40-t EAF
Our solution: We installed a new filter for primary and secondary suction with a quenching tower cooler.
The result: The new quenching tower allows greater control at temperature peaks.
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Completely Integrated Solutions with Siemens VAI
Integrated offerings for higher plant performance
Optimized processes
We lay the foundation for optimized processes with proven, leading products worldwide, including mechanical and technological engineering for metal production, rolling and strip processing as well as process control engineering, drive engineering and power supply. Inte-grated online and offline process models reflect decades of practical experience and help to ensure reliable, reproducible quality.
Our process engineering expertise fuses these products into complete plant solu-tions that also accommodate the upstream and downstream processes. These solu-tions are the basis for optimal resource use, minimized waiting times and reduced maintenance and spare parts costs, as well as wide flexibility with respect to raw materials and the resulting products.
Efficient production control
A further factor for competitive produc-tion is the quality of informaproduc-tion process-ing. Production data must be consoli-dated and compared with planning data to ensure optimal production flow. As a leading supplier for the metals indus-try Siemens VAI offers integrated infor-mation technology across all autoinfor-mation levels – from the sensor to the Enterprise Resource Planning system. Patented solutions, such as for smelting reduction plants, electric arc furnaces, hot strip mills, profile rolling or processing lines, enable systematic quality assurance, efficient logistics, flexible production planning and scheduling, end-to-end tracking and tracing from raw materials to the end product and back, and much more.
Maximized life-cycle returns
Services from Siemens VAI help to ensure high profitability for your plant through-out the entire life-cycle. Reliable project implementation by our specialists sets the course for quick start-up and repay-ment of funds as scheduled.
During the operating phase, preventive maintenance, standardized components and component design that meets the requirements of steel plants help keep maintenance costs low. A reliable spare parts supply – with in-house workshops for key components – ensures high avail-ability. And modernization at the right time guarantees a high level of competi-tiveness and compliance with environ-mental regulations in the future.
Higher availability
Measurable process improvement
Greater productivity
Integrated information technology
Reduced life-cycle costs
Maximum protection of your investment
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Perfect integration of every aspect
Completely Integrated Solutions from Siemens VAI – your benefits from an integrated concept:
High process quality, lower energy costs and in-creased throughput – by taking all process steps into account
Reproducible high product quality and efficient use of charging materials – thanks to integrated process models
High enterprise quality, low life-cycle costs and unique investment protection – through flexible production based on metal-specific MES systems, intelligent plant design and integrated planning.
Completely Integrated Solutions offer
a comprehensive range of products
and services, tailored and refined to the
specific requirements of your plant.
The key to this approach is the close
inter-linking of plant construction, process
engineering, electrical and automation
engineering, sensors and actuators, as
well as information technology and
life-cycle services, seamlessly integrated
by Siemens VAI.
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www.siemens-vai.com
For further information, please contact:
Siemens VAI
Metals Technologies S.R.L. Via Leonardo da Vinci 20 21053 Castellanza – Varese, Italy Phone: +39 0 331 741211 E-mail: environment.metals @siemens.com
Headquarters: Siemens VAI
Metals Technologies GmbH & Co. P.O. Box 4, Turmstr. 44
A 4031 Linz, Austria
E-mail: [email protected]
The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the re-spective characteristics shall only exist if expressly agreed in the terms of contract.
Order No.: E10001-M3-A4-V2-7600 Printed in Germany
Dispo No.: 21661 K-No.: 28103 GB C-MTIS5207M13 WS 05071.5 Subject to change without prior notice
Siemens AG
©Siemens AG 2006. All rights reserved.
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