Cvs Presentation

CVS MAKİNA
İNŞAAT SAN. ve TİC.LTD.ŞTİ
theMill for Minimills

GOOD COMBINATION OF OPERATIONAL PEOPLE AND DESIGNERS
WE ARE IN THE CORE OF STEEL – CVS MAKINA
D. ERTAS – CVS MAKINA – Project And Contracting Department

Located in the industrial region of Gebze, just east of Istanbul, close to many major ports, 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. Additional to technical assistance and consulting service to steel
Production and Rolling, CVS manufactures spare parts & components for steel sector.

Having more than 40,000 sqm of closed area and additional approx. 40,000 sqm open area, 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.

From Water Cooled Panels to complete Electric Arc Furnaces, from Ladles to complete Ladle
Furnaces, from Tundishes to complete Continuous Casting Machines, from Ducts to complete Fume
Treatment Systems and from Engineering Services to Turn-Key Plants, CVS offers economically viable
solutions at European standards.

CVS general plant design foceses low production costs, higher process flexibility,iIncreasing
productivity while improving energy efficiency, İmproving the quality of the finished product, Meet
environmental requirements at a minimum cost and Better coordination of process/environmental
requirements

EAF

Steelmaking is always a growing sector and steelmakers are always asking for more flexible and more
easy operation for meltshop units. As design, manufacturing and erection of this kind of units, CVS
Machina put his experience for combining more simple design with flexible operation. Additionally,
CVS fulfills any requirement when it comes to the choice of furnace type and melting technology for
cost efficient operation. Options include burners, wall mounted supersonic lances, and bottom

CVS MAKINA İNŞ. SAN. ve TİC. LTD. ŞTİ.
Dilovası Organize Sanayii Bölgesi 3. Kısım Muallimköy Cad. No:21 Gebze 41400 KOCAELİ / TURKEY
Tel. +90 262 759 15 05 Fax. +90 262 759 18 80 www.cvs.com.tr cvs@cvs.com.tr

CVS MAKİNA

tuyeres for oxygen injection to name a few. The basis of all CVS design is good accessibility, low
maintenance and operational reliability.

The CVS electric steelmaking technology is the solution for strong, simple and reliable design. As the
product of continuous development improvements, our furnaces features maximized power-on-
time, high-speed movements and easy access to all components for maintenance. The furnace is
ideal for ultra-high-power input and overall furnace performance can be additionally enhanced with
the latest oxygen and carbon injection technologies.

150 TON EAF VIEW TYPICAL FURNACE DESIGN

CVS has more than 50 Electric Arc Furnaces supplied worldwide with furnace sizes ranging between
12 to 180 tapped steel.

Electric Arc Furnace (EAF) design condiders always for short tap-to-tap times thanks to several
technologies such as:
- UHP (Ultra High Power) design, with high secondary voltages and longer arc
- High-current-conducting electrode arms in copper-clad box design
- State-of-the-art electrode control system
- Extensive use of alternative energy sources (chemical energy)
- Better energy and thermal balance inside the furnace thanks to the multiunit injection.
- High yield of alloy additives and high ladle refractory life thanks to EBT slag-free tapping.
- More heat input in cold EBT area thanks to special design of EBT-burner system.
- Heavy construction design to sustain hard working conditions, allowing very fast movements
and safe operations.
- High flexibility and high efficiency of furnace operation with closed slag door application.


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- Easy maintenance operation for special design like roof lifting system, furnace locking
system.
- Split-shell design
- Copper or combi-panels with high-speed cooling water flow
- Continuous DRI/HBI feeding systems
- Additional chemical energy based on carbon, fuel and oxygen is used as substitute of electric
power.
- SIM-ARC electrode regulation design
- Hot heel practice
- Fast scrap charging
- Scrap yard flexibility.

Electrode movements of EAF are controlled by SIM-ARC electrode regulation system which allows a
constant ratio between electrode voltage and current to be maintained. Together with the hydraulic
system of electrode movement control, system acts on arc voltage to maximise the efficiency of
melting process. Using special algorithm following benefits can be obtained:
- Fast adjustment of arc length,
- Fast response and fast and stable control,
- Minimizing of power consumption,
- Minimizing of flicker effects due to regulation quality,
- Minimizing of electrode and refractory consumption.

CVS has special oxy-burner system for higher productivity. The injection system consists of a set of jet
burners installed on the EAF shell. The jet burners are supersonic oxygen injectors combined with a
hydrocarbon burner, all in the same housing. Installed in the upper shell’s side wall, The jet burners
have functions of decarburization of the steel bath, thermal energy input, formation of foaming slag,
reduced need of charge carbon with the scrap, the thermal energy is efficiently transferred to the
bath with less fuel, lower offgas temperature and much better control of CO emissions. The location
and the direction of the burners are determined to reduce the cold spots effect generated by the
three-phase arc of the furnace, thus obtaining an even and faster melting.


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The evolution in electric arc furnace technology has progresively led to the utilisation of alternative
energy contributing to the heat balance, optimising the consumption of electrical energy and
increasing productivity. A further effect of the correct adoption of this practice is the formation of a
high level of foaming slag, with all the benefits arising from the resulting arc coverage. To obtain
better slag foaming, additional slag door manipulator with two oxygen and one carbon lance is
installed which yields faster operation.

Burners are distributed for the aim to cancel cold spot areas and also to obtain good foamy slag. In
other words, the configuration was selected in order to have an as homogenous as possible supply of
chemical energy to the bath. The module philosophy follows the target of efficient management of
electrical and chemical energy, combining efficient dynamic control of the electric arc with a
balanced injection of oxygen and carbon in order to increase EAF productivity.

BURNER DISTRIBUTION INSIDE THE FURNACE SUPERSONIC FLAME SHAPE

In addition to oxy-fuel burners, the lance manipulator for the Electric Arc Furnace is primarily
designed for safe oxygen injection. As well, solid materials like Carbon can be given from burner
case. The Carbon injection in the bath have demonstrated of outmost importance to work with
proper foaming of the slag and to obtain recarburisation of liquid steel bath if required to control
bath composition.

The carbon injectors provide the possibility to control the bath conditions by regulating the flowrate
and promoting slag foaming. This slag condition has many advantages in terms of furnace wall
protection, more efficient power utilisation and reduced maintenance.

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Foaming slag is used to increase the thermal efficiency of the furnace during the refining period,
when the side walls are fully exposed to the arc radiation. A foaming slag will rise and cover the
electric arcs, thus permitting the use of a high tap setting without increasing the thermal load on the
furnace walls. In addition, an electrical arc covered by a foaming slag will have a higher efficiency in
transferring the energy into the steel phase. Slag foaming is obtained by injecting oxygen into the
liquid steel, where mainly iron is oxidized according to the reaction:
O2 + 2 Fe = 2 (FeO)
Carbon powder is then injected simultaneously into the slag
phase where iron oxide is reduced.
(FeO) + C = Fe + CO (g)
The resulting CO gas is a critical component in order to
obtain a foaming slag.

LADLE FURNACE
The final quality of the steel is obtained by means of a powerful ladle furnace capable of operating in
accordance with the required short tap-to-tap times. The furnace is conceived for reheating the steel
in the ladle placed on a ladle car and is designed and built according to the most modern techniques
in the field and is in particular provided with:
- Water cooled ladle roof equipped with indirect fume collecting hood to reduce steel
oxidation.
- Roof lifting mechanism, with hydraulic cylinder.
- Electrode arms with reduced electrode pitch diameter.
- Water cooled secondary circuit and water cooled flexible cables.
- Electro-hydraulic electrode regulation.

The advantages of a ladle furnace are saving of ferroalloy,
saving of energy, increasing productivity, decreasing
refining time of EAF, decreasing tapping temperature at
EAF, precise temperature control, improved of inclusions,
cleanliness of the steel, possibilities of wrong analysis
limited.


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VD / VOD Plant

The purpose of secondary metallurgical steel
treatment under vacuum conditions is to
produce high-purity steel with low content of
harmful elements such as sulphur, phosphorus,
trace elements and/or carbon, lowering of
oxygen, nitrogen and hydrogen gases dissolved
in the steel, as well as major improvements of
steel purity, including shape control of non-
metallic inclusions.

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

CVS expertise extends to all types of Secondary Metallurgy Vacuum Processes: VD, VOD, VT, RH, VIM.
The sizes of the installations delivered to industry by CVS ranges from 6t up to 230t. Standard Design
for 12 t; 50t, 80t, 100t.

DRY MECHANICAL PUMPS TYPICAL VD DESIGN


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CVS has developed an efficient Filter System which brings operational benefits in regards with other
suppliers. The filter technology allow an almost perfect dust separation with a very small pressure
drop, withstand the harsh conditions of the process without being damaged by temperature and
ignition of the dust, Automatic System for Integrity Filter Monitoring as the filter damage may
result in pumps destruction. The Filter System developed by CVS has efficiency of 99% gas load is less
than 5 mg/m3, Pressure drop of 0.1-0.2 mbar and operational temperature range between 20 -
1000° C

CONTINUOUS CASTIN MACHINES

CCM can be designed for the production of structural, low-carbon low alloy steels, high alloy steels,
Si-killed and Al-killed steels including free cutting stells. Billets up to 220 mm square and rounds up to
400 mm can be cast from the machine. The CCM can be designed with 2 to 8 strands and 5 to 9
meter radius and cartridge type multi-tapered moulds with the length ranging between 750 mm to
1.000 mm according to Production requirements.

CVS CCM design gives flexibility with two casting modes; open stream casting and closed casting for
special steel grades and Al-killed steels. In open stream casting, the fast nozzle changing device is
normally used for long casting sequences in order to reach very good productivity and reliability
levels.

T-shaped tundish design with high nominal capacity promotes inclusion removal, assuring a stable
steel flow, increasing steel residence time and homogenization for temperature patterns between
strands. The use of pool type impact pad also helps in creating a good steel flow pattern and an even


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temperature through the tundish. The temperature difference between hot nad cold spots is
designed to be less than 10°C.

The flow between ladle and tundish is with an automatically controlled slide gate system. Weight
cells on cantilever type tundish car measure the weight of liquid steel in the tundish and
automatically open or close the ladle slide gate to maintain the depth of steel required. For inclusion
control, ladle shroud can be applied. Additionally, tundish automatic weight control can be
implemented by small additions to slide-gate hydraulic unit and automation system.

Mould technology with long copper mould and tapered design yields for high casting speed by
increasing heat transfer equally all around the mould. Thanks to the multi-tapered design, the air gap
that is formed inside the mould is reducing. Air gap is normally formed because of in the lower part
of the mould by billet shrinkage and in the upper part by the difference in heat Exchange between
the faces and corners.

Quick and safe mould changing can be achieved by cartridge type mould yielding pre-assembled and
self-centering design, together with self-sealing connections for cooling water supply. Foot Roll
design underneath the mould helps to overcome bulging of semi-product.

Mould External/Internal Electromagnetic Stirrers (M-EMS) and/or final EMS (F-EMS) can be
implemented to help improve the internal structure of the billet. This is an important tool when
casting high quality steels to help in the formation of the cast structure (equaxial zone), and to avoid
deposits of non-metallic or gaseous inclusions in the sub-surface area of the solidified shell. These
inclusions may lead to serious defects during the successive processes downstream of the caster.


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Magnetic or Co60 Radioactive source is used for Automatic Mould Level Control System. It controls
the liquid steel level in the by adjusting the speed of withdrawal and straightening unit variably for
open casting. Control system is not effected by the vibrations created by steel stream impact into the
tundish and by the vibration of the casting platform. It allows flying tundish change, fly nozzle change
without casting stop. Thanks to the system having high accuracy with quick response features, for
precise control of meniscus level in the mould, surface quality problems arising especially from
oscillation marks are cancelled .

The oscillating table with electro-mechanical or hydraulically driven designs is of heavy-duty design
and is sized to support the mould housings. The real oscillating curve overlaps the ideal one with
strict tolerances and is stable during machine life in order to insure quality of the billet and a longer
mould life by reducing friction between steel and copper tube. The mould oscillation system is
designed to maintain surface quality, limiting oscillation marks depth and cracks generation, to allow
an adequate lubrication of the solidifying shell, to obtain good heat transfer in mould, to get shallow
oscillation mark by short stroke and high frequency values. Automatic Break-out prediction system
and mould oscillation monitoring systems are the equipments used for better contol of operation.

The secondary cooling design is generally devided into four zones, each having its own regulation
loops. The cooling for all zones is with water by correctly balanced flowrates and pressures. Sprayer
designs of this multi zone secondary cooling system is arranged to reach the goal to avoid reheating
of strand surface and to promote the continuation of shell growth, which has very ig influence on the
internal quality of end product. Additionally, to decrease the risk of break-out and avoiding internal
crack, secondary cooling system automatically controlled in accordance with section size and casting
speed.

The withdrawal and straightening module is to carry out dummy-bar insertion and withdrawal of the
billet. A hydraulic cylinder lifts and lowers the top roll and applies the required pressure on the
dummy bar or the billet. The pressure of the rolls on the billet is adjusted highly enough to avoid
skidding on the billet surface.


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The billets are cut-to-length automatically by a mechanical shear or by a single torch oxycutting car
according to length measurement from encoder installed on withdrawal motor. As the billet reaches
the length required, shear or the oxycutting car automatically start to cut. For oxycutting torch,
Clamping action enables the car to travel forward with the same speed of the strand. After cutting
operation is finalised, clamps are opened and car returns back to park position.

After cutting, billet is transported along the run-out roller table up to billet transfer zone and lifted by
hydraulic cylinder. After completion of one billet lifted for each strand, transfer car moves them
sideways to the walking beam cooling bed. Along this unit, billet is transported by 90° rotation for
even cooling. At the end of the bed, billets are off-loaded by magnet crane and stockpiled.

SCRAP PREHEATING SYSTEM

Heat energy contained in a gas evacuated from an EAF accounts for 15 to 20 % of the total energy
used in EAF steel making process and that is 100 – 150 kwh/ton. CVS scrap pre-heater is a system
which utilizes this heat energy to heat scrap in a bucket before charged into an EAF and thus
contributes towards energy saving. Gas evacuated from the EAF is led to a combustion chamber
through a suction duct together with air induced through gap between EAF elbow and sliding sleeve
duct to burn CO contained in the gas, a part of this burned gas is introduced in to the bucket placed
at the scrap to heat scrap. After passing the bucket, the gas is returned to the combustion chamber
by a preheating fan. This is called Recycle Flow in the system.
When scrap does not contain oil and other combustibles, the gas after preheating my be sent to the
duct collector. This is called Direct Flow in the system.


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For Recycle flow, combustibles contained in the gas after preheating is burned by mixing with the gas
from the EAF. This enables to eliminate an air pollution after dust collector.
It is important to minimize gas leakage in a preheating line. For this purpose, special sealing devices
are provided between hood pipe and inlet duct, hood and scrap bucket top edge, bucket cylinder and
clamp shells.

By use of the adequate sealing devices, air introduced into the scrap pre-heater is very small. By
provision of preheating fan, existing fume treatment plant can employ the scrap preheater without
modification. As the system is fully automatically operated, this system does not require additional
worker. EAF operation will not be interrupted even if the preheating system run into a trouble.
Recycling method of preheating system can be controlled separately from dust collector system.
Proper adjustment of the preheating temperature prevents the scrap bucket from being deformed.

Condition of temperature on the preheating system:
- Inlet temperature of preheater: approx. 800°C – 200°C
- Outlet tempearture of preheater: approx. 250°C – 50°C
- Temperature of preheated scrap: approx. 400°C – 100°C
- Temperature at combustion chamber inlet widely varies between 1200°C to 300°C according to the
time and conditions of the steelmaking stages.

Outlet temperatures of the preheating system stays at low temperatures which indicates that heat
absorption by scrap is fully accomplished. Temperature of scrap indicates the difference between
upper and lower parts of the charging bucket.

Main Profit of the system is preheated scrap with average temperature is between 150°C - 200°C,
resulting energy saving is 20 – 30 kwh/ton in practice.

Carbon Handling System

Main design advantages for carbon handling system are low dust, fast pay-back, minimum
Investment, maintenance friendly design, low operation cost, higher productivity, safe and fully-
automated operation.


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Up to 5.000 ton/month 0-8 mm carbon with less than 1 % humudity can be produced from starting
Carbon of 0-100 mm and Humidity of Up to %25. Production yields less than 6 % dust emission, less
than 8 kWh/ton-C energy consumption and 30 Nm3/ton-C Natural gas consumption.

Depending on unit price of consumable items 30 USD/ton Carbon Handling Cost and 70 USD/ton
saving from operation can be achieved which yields investment pay-back of around only 10-months.

FTP DESIGN
From EAF Roof Elbow to Stack, CVS provides
complete Fume Treatment Plants with
engineering, design, manufacturing and
installation. Design considers also LF, MHS,
canoppy and other dust emitting points by the
goal of ZERO DUST EMITION to environment.
CVS offers economically viable solutions at
European standards.

CVS designs FTP to collect, suck and treat the primary and secondary emissions generated by the
EAF, the primary emission generated by the LF and the emission emitted by the Material Handling
System.

The dedusting system consists of a set of fume collection points and a set of ducting lines (water-
cooled or radiant type), which convey the various emissions to the bag fitler already under
implementation.

CVS designs FTP with the following aim: reliability, minimum operation and maintenance costs, low
residual dust content at stack, low noise emission, optimal utilization of spaces inside/ outside the
meltshop, automatic operation, “hands-off” type, and twenty-four hours operation.

Material Handling System


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Material Handling System is considered to reduce manual work and to avoid losing time-demanding
material handling and automatic operation. The main operations are the storage into bins,
extraction, weighing, transport and charging of ferroalloy, additives and fluxes into scrap bucket, into
the ladle in tapping position and to the ladle refining station. All plant functions, specifically from
storage bins up to loading to the final users, are controlled automatically. The dosage is carried out
with high accuracy to obtain maximum technical results and, at the same time, to use additives and
fluxes in the best possible way to minimize expenses. Suitable interlocks are to guarantee the right
positioning of the devices.

AUTOMATION

All meltshop is normally equipped with sophisticated automation system based on Local Area
Network supporting the PLC Unit, operator workstations. Each phase of the process can be
automatically controlled and constantly monitored to help making the various phases of the process
repeatable to guarantee the overall production cycle.


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Through the MMIs, the operator has an immediate overview of the process. They incorporate easy-
to-read graphics and user-friendly systems for rapid access and control of all phases. Alarms and
diagnostics are displayed on the screen to enable quick corrections to be carried out when necessary.

Thanks to open architecture of SQL database, parameters can be accessed not only by the operator
but also a higher level computer system which is called level 2. It is able to built a level 2 hardware &
software on level 1,5 substructure. The user access to level 1,5 can also be classified into several
authorization levels, such as operator access level, meltshop chief access level, etc.

Main aim in designing user interfaces is to create a virtual bridge between user and machine. User
interface pages on HMI screens are designed by using Siemens WinCC HMI software which offers
screens with rich graphical objects displaying process variables, such as temperature, pressure, flow,
animated graphics and status of machine. User screens can also be used to monitor machine
conditions for maintenance purposes, for instance, monitoring the total working hours of motors,
temperature variation graphics versus time, etc.

CVS ROLLING MILL

From Bar mill to Section Mill, From Chimney to complete Reheating Furnaces, from Roll Stands and
water quenching system to complete Rolling Mill Train, from Cooling Bed Area to Handling Area,
from Flying Shears to Cold Shears, Full Automation System and from Engineering Services to Turn-Key
Plants, CVS offers economically viable solutions at European standards.

All mechanical equipment incorporates the latest known and proven technology.


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- All mill stands are housingless series, which are known worldwide for their rigidity and ease
of maintenance.
- The stands can be used for producing all grades of steel up to and including stainless high
speed and high alloy steel.
- Special "robots" are used for quick roll changing thus reducing the requirement for costly
spares and stand by equipment.
- All the rolling mill stands are individually driven by motors
- Inter-stands tension of the bar can be controlled to acceptable limit.
- Improved quality of the finished product
- Reduced risk of scrap or cobbled bar.
- Flying shear is provided to remove the oversize head of the bar as it progresses down the
rolling line.
- Maintenance friendly design

Training and Technology Transfer

Whenever CVS recieves an order for steelmaking equipment, engineering services and know-how
transfer are mutually agreed upon between both parties. Thanks to our experience, there is no
question that we know that this is fundamental basis for succesful production equipment.
The second step of know-how transfer is an off-site training of customer’s engineers, technicians and
skilled workers.

The main target of training on the customer’s site is to familiarise their personel with hands-on
operation ofthe supplied machines and equipment. The operators and maintenance personel are
trained step by step to prepare them for successful operation of the equipment.


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