SMS Concast - Brasil
Seminário ABM – Maio 2012
Summary Slide
Layout
●
Mechanical Vacuum Pump
• 3-Stage Mechanical Vacuum Pump
With Steam Ejectors and Condensers
With Mechanical Vacuum Pumps
• Mechanical Vacuum Pump Configuration
Vacuum System Configuration
• Mechanical Vacuum Pumps – Blowers /
Compressors
Vacuum Bag Filter Design
• Main Technical Data
5-Stage Steam Ejector Pumps
●
Mechanical Pump Applications
• Main Data Comparison
• Operating Costs
History
Market Situation for Mechanical Pumps
Results
Hydrogen Removal
Desulphurisation
Electric Energy Consumption
Final Vacuum Pressure
Cost Comparison
●
Reference Projects
●
Recent References
Vacuum Plant Layout – With Steam Ejectors and Condensers
6
B
7
8
5-Stage Steam Ejectors Pumps
AC
SE5a
SE5b
● 6 Steam Ejectors
C2
● 2 Steam Condensers
● Steam flowrate 6.5 tph
SE4a
● Water flowrate 358 m3/h @ 35 °C in
C1
● < 5 min pump-down time
SE3
● Final operating pressure 0.5 torr
SE2
SE1
Vacuum Plant Layout – With Mechanic Vacuum Pumps
General Vacuum System Design Configuration
VD Tank
Vacuum
Bag
Filter
●
One fixed Vacuum Tank
●
One Vacuum Filter
●
One Vacuum Pump
Mechan.
Vacuum
Pumps
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
VOD Layout with Mechanic Vacuum Pumps
VOD Layout with Mechanic Vacuum Pumps
Hydrogen Removal
HYDROGEN REMOVAL
ORI MARTIN VD 75, Unfiltered Data
10.0
Hinit, ppm
Hfinal, ppm
9.0
H Content, ppm (HYDRIS)
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
1278 1539 1540 1591 2158 2404 2451 2837 2860 2861 2876 2898 2964 2985 2986 3006 3092 3137 3657
Heat #
● Time at < 1.33 hPa 10-14 min.
● Hydrogen contents of 1.5/2.0 ppm can easily be achieved
Desulphurisation
DESULPHURISATION inVD
ORI MARTIN VD 75, Unfiltered Data
0.040
Initial S content 0.020-0.030 %
Sinit, %
SafterVD, %
0.035
S Content After VD, %
0.030
0.025
0.020
0.015
0.010
0.005
13
90
14
25
15
14
15
40
15
91
16
59
16
80
16
95
17
64
17
87
18
09
18
99
21
36
24
27
25
29
28
60
28
77
28
99
29
65
30
06
30
70
30
92
36
39
36
74
37
68
0.000
Heat #
•
Initial S 0.020-0.030 % with some peaks
Final S 0.001-0.006 % without Ca treatment
Electric Energy Consumption
Energy Consumption Mechanical Vacuum Pump
ORI MARTIN VD 75
Energy Consumption, kWh/tonne
1.0
0.8
0.6
0.4
0.2
0.0
0
5
10
15
20
Vacuum Time, minutes
•
0.5-0.9 kWh/t for 22 minutes degassing time
25
30
Final Vacuum Pressure
Final Vacuum Pressure
ORI MARTIN VD 75
1.00
0.90
Final Pressure, mbar
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
Heat #
•
Typical final vacuum pressure 0.3-0.4 hPa
187
181
175
169
158
152
146
140
134
128
122
116
106
91
85
78
72
58
52
46
40
34
28
22
14
7
1
0.00
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
Mechanical Vacuum Pump Configuration
Suction
2nd Stage
1st Stage
3rd Stage
●
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
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
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 < 1.6 kWh/tonne
● Pump-down time
< 4 min
● Final operating pressure
0.5 hPa ( 0.4 torr)
Main Technical Data Comparison
Vacuum Pump type
Steam Ejector Pump
Mechanical Vacuum Pump
5-120 SE
M-47
Vacuum pump suction capacity at
0.5 torr
120 kg/h
55’750 m3/h = 47 kg/h DAE
Water flowrate
358 m3/h
5.5 m3/h
Steam consumption
6.5 tph
-
Final operating pressure
0.4 torr
0.4 torr
Final vacuum against closed shutoff valve
< 0.2 torr
< 0.05 torr
Pump-down time to 1.0 torr
< 5 min
< 4 minutes
Electric energy consumption
2 kW/tonne (WTP)
< 1.6 kWh/tonne
COMPARISON OF OPERATING COSTS
ITEM
UNIT COST
Cost,€/Unit
MECHANICAL PUMP
Spec. Consumption, Cost/tonne
units/tonne
0.052
1.6
0.083
26.00
Electric Power, kWh
Steam, tonne
Condenser Water, m3
Machine cooling water, m
STEAM EJECTOR PUMP
% Spec. Consumption, Cost/tonne
units/tonne
32.8
0.1
0.005
0.090
2.340
0.03
3
%
0.1
58.7
6
0.180
4.5
0.17
0.1
0.017
6.7
Nitrogen, Nm3
Lubricants, l
Maintenance (SE), year
Maintenance (M), year
TOTAL
0.25
4.50
50'000
4'000
0.12
0.002
0.030
0.009
11.8
3.6
0.12
0.0001
0.030
0.000
1.429
0.8
0.0
35.9
0.114 45.1
0.25 100.0
€
3.98
100.0
Annual tonnage, tonnes
Heat weight, tonnes
35'000
30
€
Diff., €/tonne
3.73
●
Main cost difference derives from steam and cooling water
●
Operating costs around 3.7 € per tonne lower with mechanical vacuum pumps
MWL – START-UP PHOTOS – VD 30 TONS
MWL – START-UP PHOTOS – VD 30 TONS
TIANJIN IRON STEEL – START-UP PHOTOS – VD 90 TONS
Others Projects of VD with Mechanical Vacuum Pumps
80-tons VD/VOD
ORI MARTIN, Italy
started up in 2002
75-tons VD
VON MOOS, Switzerland
started up in 2005
90-tons VD
KARDEMIR, Turkey
started up in 2007
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
EAF New Technological Highlights Melting
Conso Technology
• Electric Arc Furnaces UHP
up 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