POLLUTION CONTROL SOLUTIONS

BY
PROWESS INTERNATIONAL (P) LTD.
 POLLUTION CONTROL SOLUTIONS BY PROWESS

 Primary & Secondary Fume Extraction System for EAF/ LRF/EOF/AOD

 Secondary extraction through Roof canopy

 De-dusting Systems for Raw Material Handling System, Stock House, Blast Furnace Cast
House, Submerged Arc Furnace Cast House, Lime Plants etc.

 Various components of Gas Cleaning System of BOF

 Gas cooling through Gas Cooling Tower with High temperature water quenching or
Forced Draft Coolers or Natural Hair Pin Coolers

 Bag House : Pulse Jet Type or Reverse Air Bag House (RABH)

 VVVF/ Soft starter start up of ID Fan

 Complete Auto Operation through PLC with optimized Power consumption

 Pneumatically operated feedback controlled dampers

 Dust handling systems (Pneumatic Conveying & Conveying through Drag Chain
Conveyors)
 MAJOR INSTALLATIONS OF POLLUTION CONTROL SOLUTIONS BY PROWESS

Sl. No. Major Installations Year

1. Primary Fume Extraction System for 1x60T EAF of Jai Balaji Group, 2008
Durgapur
2. Revamp of Primary Fume Extraction System of 1x50T EAF of Sunflag 2008
Steel, Bhandara Road, Nagpur
3. Revamp of Primary Fume Extraction System of 1x100T EAF of Jindal 2009
Power & Steel Ltd., Raigarh
4. Primary & Secondary Fume Extraction System for 2x30T EAF + 1x30T 2010
LRF for Geco Steel, Syria
5. Primary Fume Extraction System for 1x30T EAF of Shyam Steels , 2011
Durgapur
6. Lance Trolley, Movable Tubular Hood with Car & Water-cooled Tubular 2012
Ducts for 1x60T AOD of Salem Steel (SAIL)
7. Primary & Secondary Fume Extraction System for 2x100T EAF + 4x100T 2013
LRF for Monnet Ispat & Energy Ltd., Raigarh
8. Primary & Secondary Fume Extraction System for 1x30T EAF + 1x30T 2014
LRF for Muscat Steel Melting Co. LLC. , Muscat, Oman
9. Primary & Secondary Fume Extraction System for 1x35T EAF + 1x35T 2015
LRF for Arora Iron Steel Rolling Mills Ltd., Ludhiana
10. Gas Cleaning System for 1x35T VD for Arora Iron Steel Rolling Mills Ltd., 2015
Ludhiana
11. Primary & Secondary Fume Extraction System for 1x45T EAF + 1x45T Commissioning
LRF for Sona Alloys Pvt. Ltd. , Lonand (Near Pune) due.
 FUME EXTRACTION SYSTEM
ELECTRIC ARC FURNACE & LADLE FURNACE
 FUME EXTRACTION SYSTEM
ELECTRIC ARC FURNACE & LADLE FURNACE

MECHANISM OF EAF/LF DUST FORMATION

ENTRAINMENT OF PARTICLES

VOLATILIZATION OF VOLATILE MATERIALS

CO (CARBON MONOXIDE) BUBBLE BURSTING

AMOUNT OF DUST GENERATED : 10-20 Kg/T OF CHARGED WEIGHT

 FUME EXTRACTION SYSTEM
ELECTRIC ARC FURNACE & LADLE FURNACE

MECHANISM OF CO, NOX & VOC FORMATION

OXYGEN LANCING IN THE MELT PROCESS REACTS

CO FORMATION WITH THE CARBON OF THE CHARGE-MIX AND
PRODUCES HUGE AMOUNT OF CO&CO2

NOX IS FORMED WHEN NITORGEN PASSES

NOX FORMATION THROUGH THE ARC OF THE ELECTRODES

VOC FORMS DURING INITIAL STAGE OF MELTING

VOC FORMATION WHEN ORGANIC COMPOUNDS AVAILABLE
IN CHARGE-MIX BURNS OFF
 FUME EXTRACTION SYSTEM
ELECTRIC ARC FURNACE & LADLE FURNACE

EMISSIONS FROM ELECTRIC ARC FURNACE

PRIMARY EMISSIONS SECONDARY EMISSIONS

EMISSIONS PRODUCED EMISSIONS PRODUCED

DURING MELTING& REFINING DURING CHARGING,
OPERATIONS OF DESLAGGING & TAPPING
ELECTRIC ARC FURNACE OPERATIONS OF
ELECTRIC ARC FURNACE
 FUME EXTRACTION SYSTEM
ELECTRIC ARC FURNACE & LADLE FURNACE

TYPICAL FLOW DIAGRAM OF FUME EXTRACTION SYSTEM FOR EAF , LRF & MHS
 FUME EXTRACTION SYSTEM :
2X100T + 4x100T LRF EAF AT MONNET ISPAT, RAIGARH
TECHNICAL PARAMETERS
TECHNICAL PARAMETER : FUME EXTRACTION SYSTEM : 2x100 EAF + 4x100T LRF
Volume of Fumes 22,00,000 Am3/Hr at 1160C at each Bag-house Inlet
Fixed Elbow Duct to Combustion Chamber Tubular; 3800 mm Dia. x 12.5m L
Combustion Chamber Tubular; 5m H x 7m W x 12m L
Water-cooled Duct up to Forced Draught cooler GCT/HTQ Tubular; 4000mm Dia. x 22m L
Air cooled Duct [Secondary Canopy to Secondary Junction ] ID 4800mm
Air cooled Duct [4x100T LF to Sec. Duct ] ID 900mm
Air cooled Duct [Sec. Jn. to Bag-house ] ID 6100mm
Air cooled Duct [Bag-house to ID Fan] ID 6400mm
Temp. at inlet of Gas Cooling Tower 800 - 1000 0C
Temp. at Outlet of GCT / HTQ 250 - 280 0C
Fume Temp. at ID Fan Inlet 116 0C
Common Stack (for 2x100T EAFs + 4x100T LRFs) Dia. - 10000mm (at Top) (for 2x22,00,000Am3/hr flow)
• Mist Spray on hot fumes dynamically controlled through
Gas Cooling Tower / High Temp Quenching Tower
PLC & Lances
• 2 Nos. (Each of Capacity 22,00,000 Am3/hr )
• Pulse Jet Cleaning – Off Line
Bag House • Non-Woven Type Polyester, PTFE Treated
• A to C Ratio (Net) : 1.27 m3/m2/minute
• Pr. drop across BH : 150 mm WC
• Clean Gas dust content : 40mgm/Nm3
• 4 Nos. ( 1 No. for each 100T LRF)
Booster Fan for LRF Fumes • 1,00,000 Am3/hr. at 120 0C ; Static Pr. : 300mmWC
• 110 KW @ 990rpm; 415V
• 5 Nos. (2 Nos. running simultaneously for each EAF (EAF-
1 & EAF-2) +1 No. Common Stand-by)
ID Fan for Bag House
• 11,00,000 Am3/hr. at 120 0C ;Static Pr. : 380mmWC;
• 1600 KW @ 990rpm; 6.6 KV; with VVVF Drive
 FUME EXTRACTION SYSTEM :
2X100T + 4x100T LRF EAF AT MONNET ISPAT, RAIGARH

GENERAL LAYOUT

BIGGEST FUME EXTRACTION SYSTEM FOR ANY EAF IN INDIA

 FUME EXTRACTION SYSTEM :
2X100T + 4x100T LRF EAF AT MONNET ISPAT, RAIGARH

FIXED TUBULAR DUCT FOR COMMON STACK

PRIMARY FUMES (10M DIA AT EXIT- BIGGEST
FOR ANY EAF IN INDIA)

PLAIN DUCTS FOR SECONDARY FUMES

COLLECTED THROUGH ROOF CANOPY
 FUME EXTRACTION SYSTEM :
2X100T + 4x100T LRF EAF AT MONNET ISPAT, RAIGARH

GAS COOLING TOWER (GCT) OR HIGH TEMPERATURE QUENCHING (HTQ) TOWER

TO COOL PRIMARY FUMES FROM 1200 DEG. C TO 280 DEG. C

SPRAY LANCE INSTALLATION

AT GCT

PLC CONTROLEED WATER

PUMPING & COMPRESSED AIR
GAS COOLING TOWER (GCT) VALVE STAND
 FUME EXTRACTION SYSTEM :
1x 30T EAF + 1x30T LRF AT MUSCAT STEEL MELTING CO. LLC. , MUSCAT, OMAN
TECHNICAL PARAMETERS
TECHNICAL PARAMETER : FUME EXTRACTION SYSTEM : 1x30T EAF + 1x30T LRF
Volume of Fumes 5,10,000 Am3/Hr at 1100C at each Bag-house Inlet
Fixed Elbow Duct to Combustion Chamber Tubular; 1450 mm Dia. x 6.0m L
Combustion Chamber Tubular; 2600 mm Dia. x 5.5m L
Water-cooled Duct up to Forced Draught Cooler (FDC) Tubular; 1350mm Dia. x 45.0m L
Air cooled Duct [Secondary Canopy to Mixing Chamber ] ID 2600mm
Air cooled Duct [ LF to Sec. Duct ] ID 600mm
Air cooled Duct [Mixing Chamber to Bag-house ] ID 2400mm
Air cooled Duct [Bag-house to ID Fan] ID 2800mm
Temp. at inlet of Forced Draft Cooler 500 - 550 0C
Temp. at Outlet of FDC 220 - 250 0C
Fume Temp. at ID Fan Inlet 110 0C
Stack Dia. - 3400mm x 45.0m L
• Cooling Air in tube and hot dirty fumes on tubes outer
Forced Draft Cooler (Horizontal type)
surface (3x22KW Motors for Centrifugal Fan)
• 1 No. (Capacity: 5,10,000 Am3/hr )
• Pulse Jet Cleaning – Off Line
Bag House • Non-Woven Type Polyester, PTFE Treated
• A to C Ratio (Net) : 1.3 m3/m2/minute
• Pr. drop across BH : 150 mm WC
• Clean Gas dust content : 10mgm/Nm3
• 1 No.
Booster Fan for LRF Fumes • 20,000 Am3/hr. at 140 0C ; Static Pr. : 300mmWC
• 30 KW @ 990rpm; 415V

• 3 Nos. (2 Nos. running +1 No. Stand-by)

ID Fan for Bag House • 2,55,000 Am3/hr. at 120 0C ;Static Pr. : 600mmWC;
• 600 KW @ 990rpm; 415V; with Soft Starter
 FUME EXHAUST EXTRACTION SYSTEM :
1x 30T EAF + 1x30T LRF AT MUSCAT STEEL MELTING CO. LLC. , MUSCAT, OMAN
FLOW SHEET
 FUME EXTRACTION SYSTEM :
1x 30T EAF + 1x30T LRF AT MUSCAT STEEL MELTING CO. LLC. , MUSCAT, OMAN
GENERAL LAYOUT
 FUME EXTRACTION SYSTEM :
1x30T EAF + 1x30T LRF AT MUSCAT STEEL MELTING CO. LLC. , MUSCAT, OMAN
 FUME EXTRACTION SYSTEM :
1x 35T EAF + 1x35T LRF AT ARORA IRON STEEL , LUDHIANA
FES LAYOUT
TECHNICAL PARAMETER : FUME EXTRACTION SYSTEM : 1x35T EAF + 1x35T LRF
Volume of Fumes 5,50,000 Am3/Hr at 1100C at each Bag-house Inlet
Fixed Elbow Duct to Combustion Chamber Tubular; 1450 mm Dia. x 6.0m L
Combustion Chamber Tubular; 2600 mm Dia. x 5.5m L
Water-cooled Duct up to Forced Draught cooler Tubular; 1350mm Dia. x 45.0m L
Air cooled Duct [Secondary Canopy to Mixing Chamber ] ID 2600mm
Air cooled Duct [ LF to Sec. Duct ] ID 600mm
Air cooled Duct [Mixing Chamber to Bag-house ] ID 2400mm
Air cooled Duct [Bag-house to ID Fan] ID 2800mm
Temp. at inlet of Forced Draft Cooler 500 - 550 0C
Temp. at Outlet of FDC 220 - 250 0C
Fume Temp. at ID Fan Inlet 110 0C
Stack Dia. - 3400mm x 35.0m L
• Cooling Air in tube and hot dirty fumes on tubes outer
Forced Draft Cooler (Horizontal type)
surface (3x22KW Motors for Centrifugal Fan)
• 1 No. (Capacity: 5,50,000 Am3/hr )
• Pulse Jet Cleaning – Off Line
Bag House • Non-Woven Type Polyester, PTFE Treated
• A to C Ratio (Net) : 1.3 m3/m2/minute
• Pr. drop across BH : 150 mm WC
• Clean Gas dust content : 30mgm/Nm3
• 1 No.
Booster Fan for LRF Fumes • 25,000 Am3/hr. at 140 0C ; Static Pr. : 300mmWC
• 37 KW @ 990rpm; 415V

• 3 Nos. (2 Nos. running +1 No. Stand-by)

ID Fan for Bag House • 2,75,000 Am3/hr. at 120 0C ;Static Pr. : 550mmWC;
• 600 KW @ 990rpm; 415V; with Soft Starter
 FUME EXTRACTION SYSTEM :
1x 35T EAF + 1x35T LRF AT ARORA IRON STEEL , LUDHIANA
FES LAYOUT
 GAS CLEANING SYSTEM
GAS CLEANING SYSTEM FOR 1x35T VACUUM DEGASSING UNIT
AT ARORA IRON STEEL , LUDHIANA

a) Air flow rate at Bag Filter inlet : 60,000 m3/hr at 0.67 mbar
b) Type of Bag Filter : Circular Pulse Jet Cyclonic
c) Air temperature at the Bag filter inlet : 60 deg C
d) No. of bags : 112 nos. 150 mm dia x 4000 mm
long
e) Filter media selected : PES with P84 on top
f) Total Filter Surface Area : 211m2
g) Pressure drop across bag filter : 0.12 mbar
h) Dust loading at filter inlet : Please specify
i) Dust emission limit : 30 mg/Nm3
j) Dust composition : Fines of metal oxides
k) Dust properties : Free flowing
l) Bag Filter Design criteria : To suit surge pressure of 600 –
 FUME EXTRACTION SYSTEM :
1x 60T AOD AT SALEM STEEL PLANT

LANCE CARRIAGE SYSTEM

MOVABLE DUCT WITH CAR

WATER-COOLED DUCT
 WATER-COOLED COMPONENTS FOR FUME EXTRACTION SYSTEM :
FOR LD-2 AT TATA STEEL

SKIRT WITH WATER-COOLED RING

PORTION OF WATER COOLED
HOOD
 AT TATA STEEL
PROWESS CAN OFFER FOLLOWING POLLUTION CONTROL SOLUTIONS

 Pollution Control Measures at Mines

 Dust Emission Control at Stock House

 Dust Suppression & Extraction System at RMHS of various plants like Coke Oven Plant,
Sinter Plant, Lime Plant etc.

 Cast House Fume Extraction System using VVVF Drives for ID Fans

 Modification & Up gradation in existing system to meet latest pollution norms.

 Reverse Engineering and Spares Supply for existing systems.

THANK YOU !!!