Introduction

• CVS provides turn-key plants and

equipment solutions for STEEL
SHOPS and ROLLING MILLS for
long products.
Company highlights

• Location: Gebze (Istanbul), Turkey

• Employees: 700 people (>200 engineers)

• Turnover: € 75,000,000.00 (year 2008)

• Manufacturing area: 40.000 sqm

covered
 Area of Activities - MELTSHOP

-From Water Cooled Panels to complete Electric Arc Furnaces,

-From Ladles to complete Ladle Furnaces,

-From tank to complete Vacuum Degassers

-From Tundishes to complete Continuous Casting Machines,

-From Ducts to complete Fume Treatment Systems

-From conveyors to complete Material Handling System

-From Engineering Services to Turn-Key Plants,

Area of Activities – 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,

-From Engineering Services to Turn-Key Plants,

-Full Automation System

CVS offers economically viable solutions at European standards.

 Area of Activities – TRAINING

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.

- Off-site training of customer’s engineers, technicians and skilled workers.

- On-site training in similar designed meltshops and/or Rolling Mills

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.
 Area of Activities – CONSULTANCY

Steel Structure:

Project management of engineering

companies and fabrication shops

Structural design engineering including

static and dynamic calculations

Shop drawings

Preparation of tender documents and

evaluation of bids

Quantity survey for invoicing purposes

Fabrication of steel structure

Supervision of fabrication

Design studies for economic solutions

 Area of Activities – SITE MANAGEMENT

For erection engineering, site management

and site monitoring, our professional
handling of the site ensures the quality of the
plant and guarantees adherence to both the
budget and the schedule.

In addition, our experts have experience in

dealing and working together with people
from different cultural groups. With their
social sensitivity, motivation and leadership
ability, they ensure a perfectly functioning
site.

On-site health and safety

Our staff is well trained with regard to health

and safety issues. Compliance with
international, local, customer and company
regulations is mandatory, and is assessed on
a regular basis
New developments in steel

CVS has developed a new type of

project, i.e.:

The super-flexible EAF base

Minimill concept
The Super
uper--Flexible EAF base
Minimill Concept

• CVS has supplied the same category of

E.A.F. to three steel-plants

• All EAF’s were designed as rated 130 t

capacity equipped with the latest
technologies in terms of metallurgical,
mechanical, electrical and automation
Main Design Concept

• Nr. of scrap bucket charge : 2

• Tapping weight : 130 t

• TTT : 40 – 45 min.

• Tapping temp. : 1600-1620°C

• Hot heel amount : 20-30 t

Tap--to-Tap Time Cycle
Tap

• Charging : 3 min.
• Tapping : 3 min.
• Preparation : 4 min.
(EBT filling, gunning, etc.)
Power - off Time : 10 min.
Power - on Time : 30 min.
TTT : 40 min.
Plant layout concepts

The plant layout is studied to obtain the

below results :
•Adequate size of area occupied

•Adequate number of personel required

•Optimum productivity and limited cost

•Future extension possibility

E.A.F. main features

• The main core of the steelmaking is EAF, the

complexity is coming from various types and
blends of scraps and scrap substitutes such as
DRI and HBI.
• Additional chemical energy based on carbon,
fuel and oxygen is used as substitute of electric
power.
• Due to the dynamic process input energy should
be controlled carefully.
• Slag stability

• Control the slag foaming by controlling

slag composition

• High impedance application

• SIM-ARC electrode regulation design

Slag Foaming
Other Features of E.A.F.:
E.A.F.:

• Hot heel practice

• Control of liquid steel

• Chemical energy input

• Fast scrap charging

• New roof lifting mechanism design

• Scrap yard flexibility

New EAF Roof Lifting Mechanism
CVS-- E.A.F
CVS E.A.F.. Projects
EAF Mechanical Design Features

The EAF is of “Full Platform” type i.e. with electrode lifting column
support and the roof lifting and turning machinery mounted on the
tilting platform.

The cradles are arranged so as to guarantee a tilting opposite to

the tapping side in case of a hydraulic failure.

Furnace shell of split type.

Rigid design in order to avoid distortion due to mechanical or

thermal stresses.

Curved shape in order to guarantee optimal refractory

performance.

Shell upper part of cage type and water-cooled panels with cover
plates in order to minimise air inlet.
Mechanical Design Features

Mechanical design features - Continued

Eccentric Bottom Tapping, EBT, with hydraulically operated

swivelling gate mechanism.

Roof hung in two points allowing to optimal roof closing during

melting.

Electrode lifting columns and electrode arms of stiff design

allowing for fast response electrode position control.

Hydraulic system designed for fast furnace movements and high

speed-fast response electrode position control.

The electrode hydraulic regulation uses counter pressure in order

to balance out the weight of the column, arm and power cables.
 EAF Design Benefits

Gantry design for self-supporting furnace roof

Prismatic roller-guide system for electrode masts

High-current-conducting electrode arms in copper-clad box design

State-of-the-art electrode control system

Split-shell design

Copper or combi-panels with high-speed cooling water flow

Oxygen and carbon injection

All bottom tapping systems EBT, EO-EBT, RBT, OBT)

Special hot-metal charging facilities

Continuous DRI/HBI feeding systems

EAF Main Benefits

Increased productivity due to shortest melting and idle times

High power input (up to 1 MVA/t)

High-impedance furnace

Arc voltage up to 1,500 V

Proven low-consumption values energy, electrodes, refractories, etc.)

Low tapping temperatures and minimum slag carry-over

Minimum maintenance with the use of heavy mill-type components

Highest flexibility with respect to charge materials

CVS--Burner Design Concept
CVS

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.
CVS-- Burner Positioning Inside Furnace
CVS

The lance manipulator for the Electric Arc Furnace is primarily designed for
safe oxygen injection. Same manipulator is used for carbon injection as
well.

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.
LADLE FURNACE (LF)
LADLE FURNACE (LF)

• Optimum size
• Essential part of the
secondary metallurgy
treatment
LF Advantages

• Saving of ferroalloy
• Saving of energy
• Increase 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
 LF Design Advantages

• Water-cooled ladle roof

equipped with indirect fume
collecting hood to reduce
steel oxidation
• Electro-hydraulic electrode
regulation
• Electrode arms with reduced
electrode pitch diameter
• Roof lifting mechanism via
hydraulic cylinder
 PERFORMANCES Plant A Plant B Plant C
Plant Unit: E.A.F.
Tapping weight (t) start-up 130/present 140 start-up100/present 135t start-up 130/present150
TTT (min.) 50-56 40-48 38-42 48-55 42-47 55-60
Productivity (t/h) 170 185 150 167 150-185
Electric consp.( kWh/t) 380-410 340-380 380-410 370-400 360-390
Electrode consp. (kg/t) 1.5-1.6 1.20-1.30 1.5-1.6 1.35-1.50 1.25-1.35
O2 consp. (Nm³ /t) 43 42 38 40 30-35
Carbon consp.(kg/t) 15 15-20 20 22 18-22
Refractory (kg/t) 4.20 3.60 3.67 3.35
Shell life (# of heat) 480 500 450 750
Roof delta life (heat) 520 560 450 700
Lime comp. (kg/t) 45-50 30-35 45 42 45-50
PRODUCTION
RECORD:
heat/day 32 33 37 29 29
t/day 4100 4440 3597 4013 4350
 PERFORMANCES Plant A Plant B Plant C

Plant unit: L.F.

Electric consumption 26 - 33 30 - 33 30 – 35
(kwh/t)
Electrode consumption 0.26 - 0.31 0.31 - 0.32 0.35 - 0.40
(kg/t)
Lime consumption 11 – 14 6-8 8 - 10
(kg/t)
Ladle refractory 2.5 - 2.6 2.1 - 2.3
consumption (kg/t)
Ladle life (heat) 90 - 92 80 - 95
 Company Plant A Plant B Plant C

Plant unit: E.A.F.

Furnace Type AC-EBT/Turret gantry AC-EBT/Turret gantry AC-EBT/Buggy gantry

Upper shell (Ømm) 7,200 7,200 7,200

Lower shell (Ømm) 7,400 7,400 7,400

Upper shell height (mm) 3,000 3,000 3,000

Serios reactor(MVAr) ON-LOAD 36 ON-LOAD 46 ON-LOAD

Transformer (MVA) 120+10% 135 130+20%

Max. Sec.Volt (V) 1,200 1305

Inner volume (m³) 155 155 155

Scrap bucket vol (m³) 146 130 140

Electrode (Ømm) 24” (610) 26” (660) 24” (610)

Max. Sec. Current (kA) 70 70 75

PCD (Ømm) 1300 1300 1300

Electrod arm Cu-cladded Cu-cladded Cu-cladded

Oxy/fuel burner+sup.Jet 5+1 EBT 5+1 EBT 4+1 EBT

SVC capacity (MVAr) 170 175 200

 Company Plant A Plant B Plant C
Plant unit: L.F.
Transformer (MVA) 20+20% 18+20% 20+20%

Max. Secondary 386 330 382

Voltage (V)
Max. Secondary 37 40 40
Current (kA)
Electrode (Ø, mm) 406 406 450
PCD (Ø, mm) 750 700 750
Electrode arm type Cu-cladded Bus-tube Cu-cladded
Heating rate (°C/min) Max. 5°C/min 4.5°C/min max. 5 °C/min
 Company Plant A Plant B Plant C
Plant unit: Fume Treatment Plant - FTP
Dedusting Plant: (Existing) (Existing, CVS (New CVS
Supply) Supply)
Emission type EAF primary & secondary + LF/MHS emissions
Filter Type Pulse-jet off-line Pulse-jet off-line Pulse-jet off-line
Filter surface (m²) 22.000 30.385 22.300
Main fans (m³/h) 6 x 400.000 6 x 500.000 4 x 600.000
Elect. Motors (KW) 6 x 800 6 x 1.400
Sucking capacity
2.400.000 3.000.000 2.400.000
(m³/h)
Outlet dust content
20 20 20
(mg/Nm³)
 Company Plant A Plant B Plant C
CCM Existing Existing NEW (CVS supply)
Machine Type Curved mould Curved mould Curved mould 1 m.
Radius (m) 6 5 9/17
Number of strands 7 6 6
Cast section (mm) Square 100 - 150 Square 100 - 140 Square 130 – 200
Tundish capacity (t) 30 max. 28 max. 35 max.
Mould level control magnetic camera Co-60
M-EMS yes no Yes
Oscillating unit mechanical mechanical Hydraulic
Dummy bar rigid flexible Rigid
W/S 2 drives/std 2 drives/std 3 drives/std
Billet cutting oxy-gas torch Hydraulic shear oxy-gas torch
Discharge system Liftable transfer Cross transfer Cross transfer
Billet transfer W.B. Cooling bed W.B. Cooling bed W.B. Cooling bed
Casting speed sp.140 mm 3.2 max sp.150 mm 2.8 max sp.150 mm 3.1 av.
sp.130 mm 4.1 av.
Conclusions
Conclusion s

• In the last few years, CVS has supplied nr. 3 same size
EAF’s.
• One of those projects was also a complete “turn-key”
green-field project and it has been completed in 16
months.
• The three EAF’s are using in the range of 90t to 150t
liquid steel without modifications. Since many
restrictions at their beginning stage of start-up. 160t is
expected in the near future either with high bulk
density scrap or with 3 charges.
• These superflexible approach to steel making practise
is giving significant advantages to investers in terms
of their present and future’s plans.
CVS - AUTOMATION
EAF & LF– Arc Regulation System
Arc Regulation system (ARS) for
EAF applications is the latest stage
of development which using PC
based Windows XP operating
system.

Using a special algorithm following

benefits can be offered to
customer;
- 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 -
NURSAN EAF PROJECT

NURSAN holding is one of the leader

company in Turkey, especially in South
part of Turkey. Rolling mill plant started
production in 1984.

After his fast grow, it is decided to

make investment for billet production.
New meltshop started production in
2003.

The same fast grow has been seen

thanks to well oriented, expert and
dynamic team.

In 2008, they decided to increase

furnace capacity and signed contract
with CVS for high efficiency,
environmet-friendly, maintenance free
special furnace design.
 CVS -
NURSAN EAF PROJECT

Furnace has reached 35 heats/day

average production thanks to co-
operative work between CVS and
NURSAN technical team during
design, assembly and start-up
period.
CVS -
TOSCELIK PROJECT

Start-up in 18 months
from signing of the contract
 CVS -
TOSCELIK PROJECT

TOSCELIK project is our one of our turn key project in Turkey.

TOSYALI holding was one of the leader company in Turkey especially in pipe
production. They decided to make new meltshop and rolling mill investment for
long production and slab production. They awarded CVS for comple turnkey
solution.

Turnkey Project Covers following Units:

• Steel Structure
• SVC Unit
• 130 - 160 ton AC Arc Furnace
• Ladle Furnace
• 6 strand CCM with 9 meter radius
• 2 Strand Slab Caster (Not Suplied by CVS)
• Hot strip mill (Not Supplied by CVS)
• Fume Treatment Plant
• Water Treatment Plant
• Oxygen Plant (Not Supplied by CVS)
• Other steel plant facilities
Thank You For Your Patience
www.cvs.com.tr