1 Regulatory Requirements Coke Ov en-Pushing Emissions New Mact - - PowerPoint PPT Presentation

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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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1

Industrial Accessories Company 4800 Lamar Ave Mission, Kansas 66202

Electric Arc Furnace Technologies

Corporate Background

PP003

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2 Regulatory Requirements

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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3 EAF Process Design

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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4 EAF & Ladle Furnace

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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5 DEC / 4TH Hole Exhaust

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6 Water Cooled Duct With W/C Damper

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7 Side Draft Hood Enclosure Box Design

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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8 Side Draft Hood Finger Hood Design

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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9 Canopy Hood Design

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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10 Canopy Hood Design

Design 2 830,000 ACFM 18'-0" Dia Duct Louver Damper 9'-0" X 9'-0" Tapping Melting Slagging

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11 Canopy Hood Design

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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12 IAC “M” Pulse

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:

  • 1. Design of Inlet/Outlet Plenum is preliminary
  • 2. The Header will be 12" Diameter (min).
  • 3. Pulse Valves 2 1/2" min.

INLET PLENUM (Tapered)

IP

h IPw OUTLET PLENUM (TAPERED)

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13 Side Elevation

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"

  • Compt. Length

10'-0" Baghouse Length Grade CIw

Dirty Air Housing

  • Compt. Outlet
  • Compt. Inlet

CIw

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14 Velocity Profile

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

  • Compt. Outlet - Height

ft 2.5

  • Compt. Outlet - Width

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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15 Tube-sheet Design

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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16 Plan View - One Door/Header

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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17 “M” - Pulse Baghouse Header Design Arrangement

90 Degree; Threaded, Double Diaphram Valve 3" Valve (Typical) Header

  • Typ. 3" Blow-Pipe

Roof Top Door (6" High) Outlet 8"

  • Typ. 3" Blow-Pipe (3 1/4" OD)

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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18 “M” - Pulse Baghouse

90 Degree Threaded Double Diaphragm Valve

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19 “M” - Pulse Baghouse

Full Immersion Design Header

Tank has integrated diaphragm valves controlled by remote solenoid pilots

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20 Heat Exchanger

  • 1. Forced Cooling Fan, which blows cooling air in to the inside of the cooling

tubes/pipes and the process gas is on the outside of the tube. The tubes/pipes are located horizontally.

  • 2. The hot process exhaust gases are vented to the Air to Air Heat Exchanger where they

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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21 Evaporative Cooling

Hot Gas Inlet Flow Platform for access to nozzles Access Ladder Evaporative Cooler Cooled Gas Outlet Flow

To suit

Grade

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22 Lance / Nozzle Design

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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23 Nozzle Dispersion

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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24 Radiant Cooling

Radiant Tubes (Height to suit) Expansion Joint Screw Conveyor Rotary Valve Grade

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25 Double Dump Valve Technology Pneumatic Conveying

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26 Standard Products

Pneumatic Conveying Mechanical Conveying Air Supply Equipment Valves/Flow Control Bulk Storage Baghouses

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27 Services

Engineering Evaluations System Design/Specification Field Evaluation Troubleshooting Installation & Start-up Maintenance

Scheduled/Preventive/Emergency

Bag Change-outs Equipment Upgrades/Optimization Turnkey Projects Training - Operation/Maintenance

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28 IAC Key References

Representative Reverse Air References – Iron & Steel Industry:

  • 1. Krupp Industrie

GER 1,765,000 ACFM EAF

  • 2. Hadeed Ltd.

SAU 1,059,000 ACFM EAF

  • 3. Gret Lakes Steel

USA 1,231,000 ACFM EAF

  • 4. Ferrowohlen

SWI 765,000 ACFM EAF

  • 5. Crucible Steel

USA 865,000 ACFM EAF

  • 6. CF&I

USA 540,000 ACFM EAF

  • 7. Cascade Steel

USA 486,000 ACFM EAF

  • 8. Bethlehem Steel

USA 874,000 ACFM EAF

  • 9. Nucor, Kankakee

USA 450,000 ACFM EAF

  • 10. Kaiser Steel

USA 600,000 ACFM Reladling

  • 11. Wheeling Pittsburgh

USA 180,000 ACFM Reladling Representative References – Boilers and Dry FGD:

  • 1. C&H Combustiion

USA 465,000 ACFM FBC/Incineration

  • 2. Ormet Aluminium

USA Pot Line Dry Scrubber

  • 3. Reynolds Metal

USA 141,000 ACFM Anode Bake Fce

  • 4. Intalco Aluminium

USA 168,000 ACFM Anode Bake Fce

  • 5. ICM, Nevada, IA

USA 165,000 ACFM Coal Fired Boiler

  • 6. ICM, Goldfield, IA

USA 165,000 ACFM Coal Fired Boiler

  • 7. Cemex, Fairborn, OH

USA 65,000 ACFM Alkali By-Pass

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29 Contact Information

Corporate Address: 4800 Lamar Avenue Mission, Kansas 66202 Corp Tel: (913) 384.5511 E-Mail: iaccorp@iac-intl.com Sales Tel: (800) 334.7431 Corp Fax: (913) 384.6577 Knoxville Contact: Pramodh Nijhawan 318 Saint Andrews Drive Knoxville, TN. 37922 Tel: (865) 675-7867 E-Mail: pnijhawan@iac-intl.com Fax:(865) 675-7582