CVS MAKINA - Company Presentation

CVS provides plants & equipment for minimills, also in turn-key solution. CVS covers the complete design and manufacturing activities for green-field projects as well as revamping/upgrading of existing plants and equipment. CVS manufactures spare parts & components for meltshops & rolling mills. CVS provides technical assistance consulting service to steel production.

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CVS MAKINA - Company Presentation

Quick Info
CVS headquarter is placed in the industrial region of Gebze, just east of Istanbul, close to many major ports Our modern facilities consists of more than 40,000 sqm of closed area and a land of additional approx. 40,000 sqm CVS workforce is formed by over than 500 specialized workers and engineers with a modern machinery park to undertake even the most challenging projects. Over than 200 engineers and administrative employees are involved in the design and management of the projects.

VACUUM DEGASSING UNIT

From Steam Ejector Pump to Dry Mechanical Pump, from single tank to complete Vacuum Degassing Unit and from Engineering Services to Turn-Key Plants, CVS offers economically viable solutions at European standards.

CVS Makina. Company Presentation

CVS - VD/VOD Design Concept

q CVS Provides VD/VOD units wit a joint venture company established in 2007 q Turn-key solutions provider for
Process Plants and Installations in Vacuum&Pressure Applications q SCADA Automation Projects
q

q Design and Production Facilities for

Vacuum& Pressure Systems q Automation and Software
q

q Services Provider for Energy Sector

CVS - EAF Design Main Objective

q Dry Pump technology for Vacuum System q Integrated solution for Process and Plant Automation (level 1 + 2 Automation) q Innovative Process Control: AI@SOLIS and AI@GAS q Advanced Process Simulation and Optimization q Substantial Energy Saving Solution q Environmental Safe Solution

CVS - VD/VOD Dry 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/VOD Energy and Cost Saving

Steam Ejector Spent Energy a typical VD 30 min. Degassing process: Average steam consume for a 800kg/h Steam Ejector: 16 t/h of steam 16t/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 Ejector is therefore: 7.42 MWh x 0.40 = 2.97 MWh (electric) Energy for water pumping (800m3/h): 300 kWh Total Steam Ejector Energy Consume 3.3 MWh Mechanical Pump System consumed power: 450kW x 0.5 h = 225KWh Ratio of consumed power: 3.3MWh/0.225MWh=14.6 times

15 times less energy consume

CVS - VD/VOD Higher Nitrogen and Hydrogen Elimination

q Sievert Law:

[ H eq ] = K p H 2
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 pressure at 1 mbar this means 0.66 mbar; therefore to perform degassing of the steel we need to go under this pressure In case of dry pumps pH2 is around 0.5% of total pressure therefore the degassing process is more efficient and most important can be done at higher pressure For a dry pumping system 10 mbar is a good degassing pressure

CVS - VD/VOD Clean and Environmental Friendly

No water contamination Dust concentration in exhaust gas < 5mg/m3 Global Steel Industry Requirement of Reduced Green House Emission is fully achieved by using Dry Pumping Technology instead of Steam Ejectors Saving Energy Effect on Reduced Carbon Footprint

Typical view of a Steam Ejector Pipe

CVS - VD/VOD Dry Pumping System Structure

1st Stage Roots Type Pumps Working Pressure 5-0.1 mbar 2nd Stage Roots Type Pump Working Pressure 25-5 mbar

3rd Stage Compressor Pump Working Pressure 1000-25 mbar

CVS - VD/VOD Scale of Evolution

OUTOKUMPU VOD 2X 80t Integrated Solution Process&Plant Automation CHONGQING RH 250 t Very Large Capacity VPS TMK VD 100 t Turn Key Solutions AVMIN VIM 6T High Tech Solution

MMZ VD/VOD 100 t

Proving DPT at large scale Installations COST VOD 12 t Small Scale Pilot Plant

1998

2001

2003

2007

2008

2009

CVS - VD/VOD Vacuum Technology in Secondary Metallurgy

q First Application of Dry Pumping Technology in Steel Degassing & Processing (VOD) q Patent RO118309 q 12 t VOD q Stainless Steel, Special Turbines Steel and Implant Steel

VOD 12t, Romania, 1998

CVS - VD/VOD Vacuum Technology in Secondary Metallurgy

VD/VOD100t, Moldova, 2001

q VD/VOD 100 t q First Application of Dry Pumping Technology at large Degassing Plants q Low Carbon Steel q Stage 1: 14 x GV 400 Drystar Pumps q Stage 2: 3 x HV 14000 Dresser Roots Blowers q Stage 3: 4 x HV 30000 Dresser Roots Blowers

Stage 3

Stage 2

Stage 1

CVS - VD/VOD Vacuum Technology in Secondary Metallurgy

q Vacuum Induction Melting and Casting Furnace q 6 t capacity q Application: Special Steel for Space Industry q High Vacuum Processing Technology: 10-5 mbar q Vacuum Pumps: Dry + Roots Blowers + Vapor Boosters
A6t, South Africa, 2003

CVS - VD/VOD Vacuum Technology in Secondary Metallurgy

q VD 100 t q Turn-key delivery q Application: Mechanical Pipe Steel q Low hydrogen content in 25 min process time q 3 stage vacuum system based on skid technology q 4 skids at a total of 150 kg/h @ 0.5 mbar q New design for vacuum filter and filter control system (<5 mg/m3 dust load at exhaust) q Level 1.5 automation

TMVD 100t, Romania, 2007

CVS - VD/VOD Vacuum Technology in Secondary Metallurgy

q Largest Dry Vacuum System for Steel Processing q RH 250 t q Innovative design for filter system q Application: Special Steel q Low hydrogen content in 15 min process time q 76 pumps arranged in 19 skids q 1000kg/h @ 1 mbar pump capacity q Level 1.5 automation

RH 250 t, China, 2009

CVS - VD/VOD Vacuum Technology in Secondary Metallurgy

q Twin VOD 80 t q Process Simulation & Control q Level 2 Automation q High Temperature Filter for VOD Process q On-line Chemical analysis by AI@SOLIS q Process Gas Analysis by AI@GAS q Optimized Process Technology q Application: ULC Superferritic Stainless Steel q Ultralow Nitrogen q Ultralow Sulphur

2 x VOD 80 t, Finland, 2009

CVS - VD/VOD Key Features

Compact Design q Advanced Design based on the Process Simulation CVS can size
properly the vacuum system, vacuum pipes, filter, tank/process chamber and the other process equipment using the process simulation technique

q 3D Modeling
AutoDesk Inventor 2009/2010 Package is Standard for Plant Design and Engineering

CVS - VD/VOD Key Features

Process Mathematical Models

- deH

- deC

0.025

[S], ppm 0.015 0.01 0

- deN

- deS

0.02

4 Time, mi

10

- Temperature model

CVS - VD/VOD Key Features

Mathematical Models Validation

120

400

100
300

4 Calculated, ppm

80 Calculated, ppm
Calculated, ppm

60

200

40
100

20

0 0 1 2 3 Ana lyzed, ppm 4 5 6

0 0 20 40 60 Ana lyzed, ppm 80 100 120

0 0 100 200 Analyzed, ppm 300 400

Experimental vs Model

state of the art accuracy advanced auto-tuning techniques for parameter optimization based on measured data

CVS - VD/VOD Key Features

Versatile Design
q CVS expertise extends to all types of Secondary Metallurgy Vacuum Processes: VD, VOD, VT, RH, VIM q AI has designed at least one of each during the 10 years of activity in SD q The sizes of the installations delivered to industry by CVSs Process Engineering Division ranges from 6t up to 230t. Standard Design for 12 t; 50t, 80t, 100t.

CVS - VD/VOD Key Features

Innovation Filtration Equipment q Mechanical Pumping Technology for Steel Degassing has as a key issue for reliable operation: the filtration technology used to separate the dust from the flow stream CVS has developed an efficient Filter System which brings operational benefits in regards with other suppliers q The filter technology must respond at minimum three tasks

q allow an almost perfect dust separation with a very small pressure drop q withstand the harsh conditions of the process without being damaged by temperature and ignition of the dust q Automatic System for Integrity Filter Monitoring as the filter damage may result in pumps destruction

CVS - VD/VOD Key Features

Innovation Filtration Equipment The Filter System developed By CVSs engineers responds to all three key demands: q Efficiency of 99% gas load is less than 5 mg/m3 q Pressure drop: 0.1-0.2 mbar pressure drop; q Operational temperature range: (20 -1000)o C

CVS - VD/VOD Key Features

Level 1 Software

CVS - VD/VOD Key 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/VOD Key Features

Hardware Architecture
Modules located and running on :

L1 Simulator

OPC Server

modular architecture
99.9% guaranteed availability low maintenance

L2A Primary/Production Server L2A Failsafe/Test Server

L2A Server

Configuration Best Practices Troubleshooting Historical Logs

Database

L3 Simulator

To L1 Interface Server

To Calculation Server

To L3 Interface Server

To HMI

CVS - VD/VOD Key Features

Full Automatic Process Control

the metallurgical process is fully controlled by the level 2 software the operator is provided with one-look process status however, the operator can easily at any moment take control by overriding the level 2 software

CVS - VD/VOD Key Features

Process Design

unlimited flexibility in process design technological objects approach once established a best practice procedure through simulations, cost analysis and hot tests, the software will automatically follow it

CVS - VD/VOD Key Features

Offline Process Simulation
1000

100

vessel pressure, mbar

10

presiune la rece mbar presiune la cald mbar

1 0 5 10 15 20 25 30 35 40

0.1 time, min

Hydrogen content in steel, ppm

great tool in process design

0 0 5 10 15 20 time, min 25 30

through process mathematical modeling, the need of industrial tests is greatly reduced - thus significantly reducing costs

CVS - VD/VOD Key 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 these advanced analytical tools. The calculations are validated through a validation engine, this greatly improving the mathematical models accuracy

CVS - VD/VOD Key Features

- Precise and fast off-gas analysis - Better process control through double-checking the process model results and error correction mechanisms

CVS - VD/VOD Key Features

- On-line steel chemistry analysis - On-line slag chemistry analysis - On-line steel temperature measurement

CVS - VD/VOD Key Features