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Industrial Accessories Company 4800 Lamar Ave Mission, Kansas 66202
Electric Arc Furnace Technologies
Corporate Background
PP003
1 Regulatory Requirements Coke Ov en-Pushing Emissions New Mact - - PowerPoint PPT Presentation
Industrial Accessories Company 4800 Lamar Ave Mission, Kansas 66202 Electric Arc Furnace Corporate Technologies Background www.iac-intl.com PP003 1 Regulatory Requirements Coke Ov en-Pushing Emissions New Mact Standards for Opacity
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PP003
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Coke Ov en-Pushing Emissions New Mact Standards for Opacity (20% opacity during push). Will require more efficient capture. May require capture of "travel" emissions. Blast Furnaces May require retrofit from ESP &/or Venturi Scrubber to Baghouse Primarily FF, howev er there are 2 VS installations. PM control - 0.009 gr/dscf Opacity - 20% for existing plants; 15% for new plants. Basic Oxygen Furnace (BOF) All US "Open or Closed Hood" designs hav e either an ESP or VS. Primary Control BOPF w/Closed Hood - 0.024 gr/dscf BOPF w/Open Hood - 0.019 gr/dscf Secondary Control 0.01 gr/dscf for existing plants 0.0052 gr/dsf for new plants Electric Arc Furnace (EAF) EAF Control Device: Lead Emissions of 0.0002 grains/DSF EAF Control Device: Opacity of 3% Melt Shop Building Roof Ventilators: Opacity of 6% EU dev eloping new standards for EAF emissions for following: * arsenic; cadmium; nickel; and Polyaromatic hydrocarbons (PAHs) * Once standards get adopted, US market will also be affected. Sinter Plants Windbox Exhaust 0.3 lbs per ton of product sinter (old & new plants) Discharge End 0.02 gr/dscf - existing plant; 0.01 gr/dscf - new plant 20% opacity for secondary emissions - existing plant 10% opacity for secondary emissions - new plant Cooler stacks 0.03 gr/dscf - existing plant; 0.01 gr/dscf - new plant. General Bag leak detection systems Opacity Monitoring Continuous parameter monitoring system Record keeping For Steel installations, the general accepted limit is 0.0052 gr/dscf
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Bleed-In-Air Damper Opposed Blade Damper Break Flange/Retractable Duct Water Cooled/Refractory Duct Pressure Sensor Fce Elbow W/C or Refractory To Baghouse / ID Fans (Suction or Pressure Design) Water Cooled/Refractory Duct
Electric Arc Furnace
Combustion Chamber Quench Tow er Canopy Hood Louver Damper
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Canopy Hood Louver Control Damper Combustion Chamber Electric Arc Furnace Break Flange / Retractable Duct Bleed in Air Damper Damper Hot Quenching Ladle Furnace Break Flange / Retractable Duct
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E le c t r o d e s E L E C T R O D E C la m p h o ld e r F u r n a c e M a s t h o ld in g t h e e le c tr o d e s B r a c k e t s F u r n a c e M a s t h o ld in g t h e e le c tr o d e s H o o d w it h t o p p la t e a n d o p e n b o t t o m A t th is en d , th e h o o d w ill h a v e lo u v e r s , w h ich c a n b e m a n u a lly a d ju s te d . T h is w ill a llo w d ilu tio n a ir to e n te r a n d to d iv e r t th e fu m e s c o m in g o u t o f th e e le c tr o d e h o le s . E le c t r o d e H o le O p e n in g s (3 ” m in . c le a r a n c e f o r t h e e le c tr o d e ) T h e a b o v e h o o d d e s ig n c a n b e in s ta lle d b e tw e e n th e m a s t a n d to c o lle c t th e e m is s io n s th a t e s c a p e b e tw e e n th e a n n u la r s p a c e b e t w e e n th e e le c tr o d e a n d th e fu r n a c e r o o f h o le s fo r th e e le c tr o d e s . I n u s in g th is d e s ig n , th e fo llo w in g m u s t b e r e v ie w e d c a r e fu lly : 1 . T h e m a s t h o ld in g th e e le c tr o d e s c a n o n ly b e lo w e r e d to a p o in t a b o v e th e h o o d . T h is w ill lim it th e m a s t m o v e m e n t. In m o s t E A F ’ s th is is a c c e p ta b le . 2 . T h e h o o d w ill h a v e to b e s tr e s s r e lie v e d a n d c o n s tr u c te d o f S S 3 1 7 - L . In o p e r a tio n , th e h o o d w ill ta k e a n in itia l w a r p a n d th e n w ill s ta b iliz e . 3 . T h e d u c t ta k e - o f f fr o m th e h o o d w ill h a v e a b r e a k fla n g e to a c c o m m o d a te th e r o o f s w in g .
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To Baghouse Pivot Point for Roof Break Flange Furnace Roof Mast Slag Door with Vent Pour Spout EXHAUST LOCATION Around Electrodes Slag Door Tap Spout is plugged for the Melt Cycle Design allows for cooling Air at Breakflange. Exhaust to Baghouse at 250 F.
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Design 1 830,000 ACFM 18'-0" Dia Duct Louver Damper Louver Damper 9'-0" X 9'-0" 9'-0" X 9'-0" Tapping Melting Slagging
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Design 2 830,000 ACFM 18'-0" Dia Duct Louver Damper 9'-0" X 9'-0" Tapping Melting Slagging
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RELADLING OPERATION CANOPY HOOD DESIGN Low Profile Canopy Hood w/Two Discharge Ducts (each w/inner duct) Side Discharge B HLP A X Y D E C Note: Hood is located above Crane Locate Hood as close as possible to the top of the ladle Dimensions not provided, are assumed Y 5.5 m 7 m X 3 m 4.5 m C 2 m 2.6 m D 4 m 4 m E 1.1 m 1.5 m A 6.6 m 8.1 m B 8 m 10.5 m HLP 3 m 4 m HTC 5.5 m 6.7 m
Low Profile Hood (acfm)
142,000 228,868
Low Profile Hood (am3/hr)
241,258 388,847
Traditional Hood (acfm)
170,400 274,641 Traditional Canopy Design Top Discharge HTC B A X Y C
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IAC "M" PULSE MODEL
Condition Flow Temp (F) IAC M-PULSE Baghouse
EAF 217,000 acfm 250 6 X 234TB-BHWT-360:S6 12 Penthouse w/Monorail 2 ~ 6'-0" Pneumatically Operated Roof Door Outlet Poppet Dampers 14'-0" One/Compt. 3'-6" Compt Outlet 23'-6" 9'-0" Inlet Damper Manual/Butterfly Hd 2'-6" 60 Deg Side Angle 12"x12" W To Suit Grade Baghouse Width
ELEVATION - TYPICAL SECTION THRU COMPARTMENT
Note:
INLET PLENUM (Tapered)
IP
h IPw OUTLET PLENUM (TAPERED)
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IAC "M" PULSE MODEL
Condition Flow Temp (F) IAC M-PULSE Baghouse
EAF 217,000 acfm 250 6 X 234TB-BHWT-360:S6 ~ 6'-0" 14'-0" 3'-6"
3'-0"
OPh 23'-6" IPh A CIh 6" Hd 12" x 12"
10'-0" Baghouse Length Grade CIw
Dirty Air Housing
CIw
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IAC "M" PULSE MODEL
Compt length "L" Poppet Damper
EAF
Plenum Width
Flow: acfm 217,000 # of Compts. 6 Flow to One Compt. acfm 36,167 W ft 15.7 L ft 15.0 Inlet Damper-Height ft 3.5
Outlet Plenum Height
Inlet Damper-Width ft 6.89
ft 2.5
ft 8.0 Poppet Damper Size in. 48 Inlet/Outlet Plenum Width ft 10.5 Inlet/Outlet Plenum Height ft 5.9 VELOCITY PROFILE: Inlet Plenum: fpm 3500
Inlet Plenum Height
A Across Inlet Damper fpm 1500 B 40% Flow to Hopper fpm 386 C 60% Flow to Casing fpm 579 D In to Upper Casing fpm 132 E From Hopper fpm 73 F Exit from Compt fpm 1800 G Across Poppet fpm 2878 H Outlet Plenum: fpm 3500
Inlet Damper 2'-6" Compt width "W"
INLET PLENUM F D C B E OUTLET PLENUM
H
G
A
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IAC "M" PULSE MODEL
W 14" 8" 8" 11" (typ) 8" Row s L Inlet Flow Bags/Blow Pipe 2'-6" NOTE: Tube sheet dimensions are approximate. Internal stiffners for common wall construction may extend width. PROJECT EAF BAGS/COMPT 360 # ROWS 20 BAGS/BLOWPIPE 18 W (FT) 15.67 L (FT) 15.00
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IAC "M" PULSE MODEL
Condition Flow F IAC M-PULSE Baghouse
EAF 217,000 acfm 250 6 X 234TB-BHWT-360:S6
Inlet
Outlet Baghouse Width (Bw) Baghouse Length (Bl) EAF
# Compartments 6 Flow: acfm 217,000 Compartment Width ft 15.67 Compartment Length ft 15.00 Baghouse Width ft 41.8 Baghouse Length ft 45.0
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90 Degree; Threaded, Double Diaphram Valve 3" Valve (Typical) Header
Roof Top Door (6" High) Outlet 8"
2" Overlap Nozzle 2" 6" (1 1/4" Sch 40) 3/16" Plate Tube sheet Tube Sheet Hole: 6 1/4" Bag & Cage: 6" Diameter Cage: 5 3/4" Dia. Inner Strike Plate Bag to wall clearance is 3" (min) Inlet Flow
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tubes/pipes and the process gas is on the outside of the tube. The tubes/pipes are located horizontally.
pass through vertical parallel tubes. Cooling is accomplished by forced convection induced by cross-flow fans moving ambient air over the outside of the tubes.
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Hot Gas Inlet Flow Platform for access to nozzles Access Ladder Evaporative Cooler Cooled Gas Outlet Flow
To suit
Grade
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Lance Assembly is constructed in 316 SS
8" 150lb. Flange standard (1" / 25.4 mm thick) 13.5" OD (342.9 mm) 11.75" 298.5 mm) Diameter bolt hole center 7.5" 190.5 mm Distance to suit Cooler Size Liquid Inlet 1" NPT or BSPT 8.23" (209.1 mm) 2 1/2" sch 40 pipe 2.75" (69.9 mm Hex 4" 2.875" OD Nozzle Tip has 8 holes (free passage) Air Inlet 1" NPT or BSPT
Nozzle Tip Configuration
Spray Velocity designed in the range of 80 to 125 ft/sec (24.5 to 38.2 m/s)
0.188" (4.7 mm) to 0.393" (9.9 mm) 8 Holes 2.38" (60.3 mm) to 2.75" (69.9 mm)
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48"/1.22M v
y
Spray Velocity
"z"
A diameter B Diameter
NOZZLE PERFORMANCE REQUIREMENT US UNITS METRIC UNITS Atomizing Air Pressure: 20 / 40 / 60 / 70 / 80 psi 1.38 / 2.76 / 4.14 / 4.83 / 5.52 bar Liquid Pressure: 13.9 to 95.5 psi 0.96 to 6.59 bar Liquid Capacity: 0.5 to 30 gpm 1.89 to 113.56 l/min NOZZLE DISPERSION ANALYSIS: 1 Spray Dimensions (y; and z) 2 Spray Velocity (v) 3 Spray Cloud Diameter (A & B)
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Radiant Tubes (Height to suit) Expansion Joint Screw Conveyor Rotary Valve Grade
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Representative Reverse Air References – Iron & Steel Industry:
GER 1,765,000 ACFM EAF
SAU 1,059,000 ACFM EAF
USA 1,231,000 ACFM EAF
SWI 765,000 ACFM EAF
USA 865,000 ACFM EAF
USA 540,000 ACFM EAF
USA 486,000 ACFM EAF
USA 874,000 ACFM EAF
USA 450,000 ACFM EAF
USA 600,000 ACFM Reladling
USA 180,000 ACFM Reladling Representative References – Boilers and Dry FGD:
USA 465,000 ACFM FBC/Incineration
USA Pot Line Dry Scrubber
USA 141,000 ACFM Anode Bake Fce
USA 168,000 ACFM Anode Bake Fce
USA 165,000 ACFM Coal Fired Boiler
USA 165,000 ACFM Coal Fired Boiler
USA 65,000 ACFM Alkali By-Pass
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