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Seminário ABM – Maio 2012

SMS Concast - Brasil . Seminário ABM – Maio 2012. Summary Slide. Layout With Steam Ejectors and Condensers With Mechanical Vacuum Pumps Vacuum System Configuration Vacuum Bag Filter Design 5-Stage Steam Ejector Pumps Mechanical Pump Applications History

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Seminário ABM – Maio 2012

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  1. SMS Concast - Brasil Seminário ABM – Maio 2012

  2. Summary Slide • Layout • With Steam Ejectors and Condensers • With Mechanical Vacuum Pumps • Vacuum System Configuration • Vacuum Bag Filter Design • 5-Stage Steam Ejector Pumps • Mechanical Pump Applications • History • Market Situation for Mechanical Pumps • Results • Hydrogen Removal • Desulphurisation • Electric Energy Consumption • Final Vacuum Pressure • Mechanical Vacuum Pump • 3-Stage Mechanical Vacuum Pump • Mechanical Vacuum Pump Configuration • Mechanical Vacuum Pumps – Blowers / Compressors • Main Technical Data • Cost Comparison • Main Data Comparison • Operating Costs • Reference Projects • Recent References

  3. 6 7 8 B Vacuum Plant Layout – With Steam Ejectors and Condensers

  4. AC SE5a SE5b C2 SE4a C1 SE3 SE2 SE1 5-Stage Steam Ejectors Pumps • 6 Steam Ejectors • 2 Steam Condensers • Steam flowrate 6.5 tph • Water flowrate 358 m3/h @ 35 °C in • < 5 min pump-down time • Final operating pressure 0.5 torr

  5. Vacuum Plant Layout – With Mechanic Vacuum Pumps

  6. VD Tank Vacuum Bag Filter Mechan.Vacuum Pumps General Vacuum System Design Configuration • One fixed Vacuum Tank • One Vacuum Filter • One Vacuum Pump

  7. Vacuum Bag Filter Design • SMS CONCAST State-of-the-art pollution control technology • Single filter sufficient for VD • Reverse jet cleaning with inert gas • Filter pressure drop < 0.1 hPa

  8. VOD Layout with Mechanic Vacuum Pumps

  9. VOD Layout with Mechanic Vacuum Pumps

  10. Hydrogen Removal • Time at < 1.33 hPa 10-14 min. • Hydrogen contents of 1.5/2.0 ppm can easily be achieved

  11. Desulphurisation • Initial S 0.020-0.030 % with some peaksFinal S 0.001-0.006 % without Ca treatment

  12. Electric Energy Consumption • 0.5-0.9 kWh/t for 22 minutes degassing time

  13. Final Vacuum Pressure • Typical final vacuum pressure 0.3-0.4 hPa

  14. 3-Stage Mechanical Vacuum Pump • 3 Stages • Identical, parallel modules • Each module consists of roots blowers and 1 screw compressor • Required suction capacity determines number of modules • Easily expandable • No stand-by costs

  15. Suction 1st Stage 2nd Stage 3rd Stage Mechanical Vacuum Pump Configuration • Machines mounted on common frame • Minimum inter-stage ducting • Compact installation – minimized civil works • Joint Concast-Edwards vacuum pump concept developed - steel degassing • Spare pumps available in England for shipping within 48 hrs • Edwards local service workshop in Bairro do Limão, Sao Paulo, Brazil

  16. Mechanical Vacuum Pumps – Blowers/Compressors Roots blower in 1st and 2nd stages • Double-ended screw compressor in 3rd stage • Progressive-pitch screws minimise thermal stresses

  17. Mechanical Vacuum Pump 2- module mechanical vacuum pump • Suction capacity 47 kg/h dry air @ 0.67 hPa, 20 °C • Cooling water 6 m3/h • Installed power 350 kW • Nitrogen purging 4.1 Nm3/h • Electric energy consumption VD< 1.6kWh/tonne • Pump-down time < 4 min • Final operating pressure 0.5hPa ( 0.4 torr)

  18. Main Technical Data Comparison

  19. COMPARISON OF OPERATING COSTS • Main cost difference derives from steam and cooling water • Operating costs around 3.7 € per tonne lower with mechanical vacuum pumps

  20. MWL – START-UP PHOTOS – VD 30 TONS

  21. MWL – START-UP PHOTOS – VD 30 TONS

  22. TIANJIN IRON STEEL – START-UP PHOTOS – VD 90 TONS

  23. Others Projects of VD with Mechanical Vacuum Pumps 80-tons VD/VOD ORI MARTIN, Italy started up in 2002 75-tons VDVON MOOS, Switzerlandstarted up in 2005 90-tons VDKARDEMIR, Turkeystarted up in 2007

  24. Others VD/VOD References Plants • Riva Lesegno, Italy - 80-tonne, VD - single tank with SE pump • ORI Martin, Italy, 80-tonne, VOD - double tank with M. pump • Gerdau Pinda, Brazil, VD - 100-tonne, revamping SE pump • Cogne, Italy, VD - 70-tonne, single tank with SE pump • Von Moos, Switzerland, VD - 75-tonne, double tank with M. pump • Kardemir, Turkey, VD - 90-tonne, double tank with M. pump • Riva Caronno, Italy, VD - 80-tonne, double tank with M. pump • MWL, Brazil, VD - 35-tonne; single tank with M. pump • Peiner Träger, Germany, VD – 100-tonne, double tank with M. pump • Tianjin Iron Steel, China , VD - 90 tonne, double tank with SE pump • Vallourec & Sumitomo, Brazil, VD - 140-tonne, double tank with M. pump

  25. EAF New Technological Highlights Melting Conso Technology • Electric Arc Furnaces UHPup to 270 t (AC + DC) • Electrical energy down to 200 kWh/t • Electrode graphite consumption down to 0.92 kg/t (good billets/blooms) Enhanced Slag Door

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