Industrial Accessories Company
4800 Lamar Ave
Mission, Kansas 66202
Electric Arc Furnace Corporate
Technologies
Background
www.iac-intl.com
1
PP003
Regulatory Requirements
Coke Oven-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, however 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 have 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 developing 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
www.iac-intl.com
2
EAF Process Design
Louver Damper
Canopy Hood
Bleed-In-Air Damper
Opposed Blade Damper
Break Flange/Retractable Duct
Water Cooled/Refractory Duct
Pressure Sensor
Fce Elbow Combustion
Quench
W/C or Refractory Chamber Tow er To Baghouse / ID Fans
Electric Arc Furnace (Suction or Pressure Design)
Water Cooled/Refractory Duct
www.iac-intl.com
3
EAF & Ladle Furnace
Louver Control Damper
Canopy Hood
Bleed in Air Damper
Break Flange / Damper
Retractable Duct
Combustion Chamber Hot Quenching
Electric Arc Furnace
Break Flange /
Retractable Duct
Ladle Furnace
www.iac-intl.com
4
DEC / 4TH Hole Exhaust
www.iac-intl.com
5
Water Cooled Duct With W/C Damper
www.iac-intl.com
6
Side Draft Hood
Enclosure Box Design
E lec tr 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 l d i n g t h e e le c t r o d e s
B r a ck e ts
F u r n a c e M a s t h o l d i n g t h e e le c tr o d e s
H o o d w ith to p p la te a n d o p e n b o tto m
A t th i s e n d , t h e h o o d w i l l h a v e l o u v e r s , w h i c h c a n b e m a n u a l l y a d j u s t e d . T h i s w i ll a l l o w d i l u t i o n a ir t o
e n t e r a n d t o d i v e r t t h e f u m e s c o m in g o u t o f t h e e l e c t r o d e h o l e s .
E le c t r o d e H o l e O p e n i n g s (3 ” m i n . c l e 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 i g n c a n b e in s t a l l e d b e t w e e n t h e m a s t a n d t o c o l l e c t t h e e m i s s i o n s t h a t e s c a p e b e t w e e n
t h e a n n u l a r s p a c e b e t w e e n t h e e l e c t r o d e a n d t h e f u r n a c e r o o f h o l e s f o r th e e l e c t r o d e s .
I n u s in g t h i s d e s i g n , th e f o l l o w i n g m u s t b e r e v i e w e d c a r e f u l l y :
1. T h e m a s t h o l d in g th e e l e c t r o d e s c a n o n l y b e lo w e r e d t o a p o i n t a b o v e th e h o o d . T h is w i ll lim it th e
m a s t m o v e m e n t. I n m o s t E A F ’ s t h i s i s a c c e p t a b l e .
2. T h e h o o d w i l l h a v e t o b e s t r e s s r e li e v e d a n d c o n s t r u c t e d o f S S 3 1 7 - L . I n o p e r a t i o n , th e h o o d w i l l
t a k e a n i n i t i a l w a r p a n d t h e n w i l l s ta b i l i z 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 i l l h a v e a b r e a k fl a n g e t o a c c o m m o d a t e th e r o o f s w i n g .
www.iac-intl.com
7
Side Draft Hood
Finger Hood Design
To Baghouse
Pivot Point for Roof
Break Flange
Furnace Roof Mast
Slag Door w ith Vent
Pour Spout
EXHAUST LOCATION
Around Electrodes
Slag Door
Tap Spout is plugged for the Melt Cycle
Design allow s for cooling Air at Breakflange. Exhaust to Baghouse at 250 F.
www.iac-intl.com
8
Canopy Hood Design
Des ign 1
830,000 ACFM
18'-0" Dia Duct
Louve r Dam per Louve r Dam per
9'-0" X 9'-0" 9'-0" X 9'-0"
Tapping Me lting Slagging
www.iac-intl.com
9
Canopy Hood Design
Design 2
830,000 ACFM
18'-0" Dia Duct
Louver Dam per
9'-0" X 9'-0"
Tapping Melting Slagging
www.iac-intl.com
10
Canopy Hood Design
RELADLING OPERATION
CANOPY HOOD DESIGN
Low Profile Canopy Hood w/Two Discharge Ducts (each w/inner duct)
Traditional Canopy Design Side Discharge
Top Discharge
B
HLP
HTC
A
X
A
X
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 3m 4.5 m
C 2m 2.6 m
D 4m 4 m
E 1.1 m 1.5 m
A 6.6 m 8.1 m
B 8m 10.5 m
HLP 3m 4 m
HTC 5.5 m 6.7 m
Low Profile Hood (acfm ) 142,000 228,868
Low Profile Hood (am 3/hr) 241,258 388,847
Traditional Hood (acfm ) 170,400 274,641
www.iac-intl.com
11
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 Pe nthous e w /Monorail
2
~ 6'-0"
Pne um atically Ope rated
Roof Door Outlet Poppet Dam pe rs 14'-0"
One /Com pt.
3'-6" Com pt Outle t
OUTLET PLENUM
(TAPERED)
INLET PLENUM
(Tape re d)
23'-6"
IP
h
IPw
9'-0"
Inlet Dam pe r
Manual/Butterfly
Hd
2'-6" 60 Deg Side Angle
12"x12"
W To Suit
Grade
Baghouse Width
ELEVATION - TYPICAL SECTION THRU COMPARTMENT
Note : 1. De sign of Inlet/Outle t Plenum is pre lim inary
2. The Header w ill be 12" Diam e te r (m in).
3. Puls e Valve s 2 1/2" m in.
www.iac-intl.com
12
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"
Com pt. Outle t
3'-6"
3'-0"
OPh
23'-6"
Dirty Air Hous ing
IPh
CIh Com pt. Inle t CIw
6"
CIw
Hd
12" x 12"
Com pt. Le ngth
10'-0" Baghous e Le ngth
Grade
www.iac-intl.com
13
Velocity Profile
IAC "M" PULSE MODEL
Com pt length "L" Poppet Dam per
EAF Ple num Width
Flow: acfm 217,000 F G
# of Compts. 6
Flow to One Compt. acfm 36,167
W ft 15.7 OUTLET PLENUM
L ft 15.0 H
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 D
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 Inlet Plenum Height
A Across Inlet Damper fpm 1500
B 40% Flow to Hopper fpm 386
C 60% Flow to Casing fpm 579 C
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 B A
E Inle t Dam per
2'-6"
Com pt w idth "W"
www.iac-intl.com
14
Tube-sheet Design
IAC "M" PULSE MODEL
14" 8"
8"
11" (typ)
8"
Row s
Inle t Flow
Bags /Blow Pipe 2'-6"
NOTE: Tube s hee t dim e nsions are approxim ate . Inte rnal s tiffne rs for com m on w all cons truction m ay e xte nd w idth.
PROJECT EAF
BAGS/COMPT 360
# ROWS 20
BAGS/BLOWPIPE 18
W (FT) 15.67
L (FT) 15.00
www.iac-intl.com
15
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
www.iac-intl.com
16
“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" Diam eter
Cage: 5 3/4" Dia.
Inner Strike Plate
Bag to w all clearance is 3" (m in)
Inlet Flow
www.iac-intl.com
17
“M” - Pulse Baghouse
90 Degree Threaded Double Diaphragm Valve
www.iac-intl.com
18
“M” - Pulse Baghouse
Full Immersion Design Header
Tank has integrated diaphragm valves
controlled by remote solenoid pilots
www.iac-intl.com
19
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.
www.iac-intl.com
20
Evaporative Cooling
Hot Gas Inlet Flow
Platform for access to nozzles
Access Ladder
Evaporative Cooler
Cooled Gas Outlet Flow
To suit
Grade
www.iac-intl.com
21
Lance / Nozzle Design
Lance Assembly is constructed in 316 SS
8" 150lb. Flange standard (1" / 25.4 m m thick)
13.5" OD (342.9 m m )
11.75" 298.5 m m ) Diam eter bolt hole center
7.5" 190.5 m m Distance to suit Cooler Size
Liquid Inlet
1" NPT or BSPT
8.23" (209.1 m m )
2 1/2" sch 40 pipe 2.75" (69.9 m m 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 m m ) to 0.393" (9.9 m m )
8 Holes
2.38" (60.3 m m ) to 2.75" (69.9 m m )
www.iac-intl.com
22
Nozzle Dispersion
48"/1.22M
v y
Spray Velocity
"z"
A diam eter
B Diam eter
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)
www.iac-intl.com
23
Radiant Cooling
Radiant Tubes
(Height to suit)
Expansion Joint
Screw Conveyor Rotary Valve
Grade
www.iac-intl.com
24
Double Dump Valve Technology
Pneumatic Conveying
www.iac-intl.com
25
Standard Products
Pneumatic Conveying
Mechanical Conveying
Air Supply Equipment
Valves/Flow Control
Bulk Storage
Baghouses
www.iac-intl.com
26
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
www.iac-intl.com
27
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
www.iac-intl.com
28
Contact Information
Corporate Address: 4800 Lamar Avenue
Mission, Kansas 66202
Sales Tel: (800) 334.7431
Corp Fax: (913) 384.6577
Knoxville Contact: Pramodh Nijhawan
318 Saint Andrews Drive
Knoxville, TN. 37922
Fax:(865) 675-7582
www.iac-intl.com
29
