alstom

Seminario InternacionalSoluciones 2006

Santiago de Cali, Colombia 2 y 3 de Noviembre de 2006

NovNoviiembembrere 20020066

Soluciones de Aire Limpioen la

Industria del Hierro y el Acero

Linda Ayala y Nelson Izquierdo

NovNoviemiembbrere 20020066

Environmental Control Systems

Air pollution control systems & products for power & industrial applications

A business driven by increasingly strict emissions regulations

Serving new plants & retrofitting existing plants

Our Business

Bringing you a World of Experience in Clean Air Solutions

Environmental Control Systems

Employs around 1000air pollution controlprofessionals

Located in 13 countriesaround the world

Dedicated R&D facilities

70 years experience inair pollution control

Our Organization

ALSTOMALSTOM EnvironmentalEnvironmental ControlControl SystemsSystems

1989 200019991922

DanecoItaly

1996

-- Long history in air pollution control Long history in air pollution control --

Origin and background:

ECS Corporate Headquarters + French Unit, Paris, France

Our Locations

Total: approx. 1000 employees

Knoxville

São Paulo

Kolkata

Sydney

Oslo Växjö

Helsinki

Milan

Moscow

Butzbach

Paris

Kobe

Beijing

ECS LAM Headquarters

Our Locations Latin America

Santiago

Caracas

BuenosAires

Bogotá

São Paulo

MexicoNew Office Locations

Industries we Serve

AluminiumCementGlassIron & SteelIndustrial Incineration PlantsNon-ferrousPulp & PaperPower

Iron & Steel at a Glance

Leading position worldwide as supplier of APC plants for the Iron & Steel Industry.

Over 30 years experience

More than 600 successful installations world wide

280 references for Electric Steel Shop / Mini Mill

320 references in Integrated Steel Plants

Technical excellence achieved by long experience and focused R&D efforts

Scope of Business - Air Pollution Control:

Electric Steel Shop / Mini Mills

Electric Arc Furnace (E.A.F.) - primary & secondary emissions

Argon Oxygen De-carbonisation (A.O.D.) converters -primary & secondary emissions

Ladle Furnace (L.F.) - primary & secondary emissions

Scope of Business - Noise Proofing System:

Dog-house enclosure for E.A.F.Elephant-house enclosure for E.A.F.


Integrated Steel Plants

Sinter band (primary & secondary emissions)

Dedusting with Electrostatic precipitator or Fabric Filter

SO2 and dioxin control with NID (dry de-SOx)

Pelletising plants

Secondary ventilation for stock house

Secondary ventilation for converter and mixer hall

Coke pushing de-dusting

Lime kiln de-dusting

Blast Furnace cast house ventilation

Water-Cooled Hoods and Ducting

Post-combustion Chambers

Gas Coolers - forced-draft and natural-draft types

Hot Quenching Towers

Hoods for secondary emissions

Cyclone & spark-arrestors - axial and vertical types

Fabric Filters (FF) - pulse-jet and reverse-air types

Electrostatic Precipitators (ESP) - dry and wet types

Wet Scrubbers

Product Portfolio

In House technology:

Scope of Activities

Supply of complete plants

Supply of dedicated Products

Turn-key installations of dedicated Products

Modernisation and retrofit of existing installations

Equipment and system supply:

Scope of Activities

Engineering service for complete plants and for dedicated Products

Supervision service to erection, start-up and commissioning

Post start-up services (i.e. spare parts, technical assistance, etc.)

Services:

Iron & Steel - references

Project Process Contract

Aceralia - Gijon, Spain - 2 ESPs for sinter primary gases 06 / 2004Arcelor - Fos sur Mer, France - FDA for sinter primary gases 01 / 2004Mechel, Chelyabinsk, Russia - 4 ESPs for sinter primary gases 01 / 2004

Gerdau-Cosigua, Brazil - EAF primary and secondary gases 11 / 2003Gerdau-Sao Paolo, Brazil - EAF primary and secondary gases 11 / 2003Outokumpu-Tornio, Finland - EAF primary and secondary gases 06 / 2003

Rautaruukki-Raahe, Finland - BOF and mixer secondary ventilation 05 / 2003Concast-EASRCO, Egypt - EAF primary and secondary gases 03 / 2003

List of recent references:

Selected references

Arcelor DunkerqueFRANCE

Sinter band (Secondary)start up 2000

Rautaruukki RaaheFinland

Mixer hall secondary ventilationstart up 2004

Selected references

Henningsdorfer ElektrostahlwerkeGERMANY

EAF and LF (Primary & Secondary)start up 1992

Outokumpu Stainless TornioFinland

EAF (Primary & Secondary)LF (Primary)AOD (Primary & Secondary)

start up 2003

Acerinox SPAIN

EAF (Primary & Secondary)start up 1997

Elbe StahlwerkeGERMANY


Selected references

Selected references

ALPA (Riva Group)FRANCE

EAF (Primary & Secondary)start up 2000

Gerdau PiratiniBRAZIL



NovNoviemiembbrere 20062006

Integrated Steel Plants at a Glance

More than 300 references globally

Combination of air pollution control and process know-how

Leading supplier for Sinter Band air pollution control

No. 1 supplier of ESPs for sinter band

Breakthrough technology for gas cleaning using dry FGD (SOx , HCl and dioxin removal)

Technical excellence achieved by long experience and focused R&D efforts

-- Integrated Steel Plants Integrated Steel Plants --


Integrated Steel Plants

Sinter band - primary & secondary emissions

Dedusting with Electrostatic precipitator or Fabric Filter

SO2 and dioxin removal with NID/FDA

Pelletising plants

Secondary ventilation for stock house

Secondary ventilation for converter and mixer hall


Coke pushing de-dusting

Lime kiln de-dusting


Integrated steel plants

Sinter band - primary and secondary gases


Sinter band - primary and secondary gases

Traditionally ESPs used for primary de-dusting and fabric filter for secondary de-dusting

Proven technology - references

more than 50 ESPs in operation for sinter primary

more than 70 installations (ESP and FF) of sinter secondary

ESP collecting efficiency strongly related to chloride content in dust

Integrated steel plants - Sinter band


ESP emission comparison - sinter primary gases

Integrated steel plants - sinter band


CST ARCELOR - Ougree ARCLEOR - Charleroi

Brazil Belgium Belgium

Production rate (ton/h) 680 750 310

Gas flow (Nm3/h) 1 230 000 1 100 000 500 000

ESP type 3-field 3-field 4-field

ESP control EPIC II EPIC II EPIC II

Start up year 1997 1996 2002

Measured emission (mg/Nm3) < 30 < 100 < 100

Comments Very low chloride content Dust bleed of Micropulse in 4th field

ESP performance improvements


Reduce load of alkali chlorides to ESPReduce feed of raw materials with high Cl content to sinter

band.Reduce re-circulation of ESP dust (dust bleed of)

Advanced energisationAdvanced ESP control technology (EPIC II)

Power down rappingSemipulse

Micropulse Technology

Reduction of dust resistivity SO3-injection


ALSTOM is forerunner in developing flue gas cleaning of sinter band primary gases

More stringent requirements for SOx, HCl, HF, Heavy Metals and Dioxins

ALSTOM Research and Development

Filosorption for dioxin removal - extensive pilot testing at site in Arcelor-Ougree site

FDA/NID technology for dioxin and acid gases removal -site testing, 1st installation start up in May 2005



FDA/NID - single unit operation to control HCl, HF, SOx, Heavy metals and Dioxin


Acid gases and dioxin removal

Lime and activated carbon as reagents

Extremely low particulate emission

Compact design with small footprint

Few, simple and well proven components

No effluent, dry end-product

TC ESP or Fabric Filter

Recirculation

Humidifier

Water

Reagent End Product

Integrated steel plants - Pelletising

Electrostatic precipitator (ESP) for de-dusting


Low pressure drop (250 Pa)

Low investment and maintenance cost even for large gas flows

High availability >99%


Coke oven batteries - coke pushing dedusting


Trav-L-Vent duct

Quench car hood

Trav-L-Vent car

Coke guide top suction

Coke guide front suction

Belt

Integrated steel plants - coke pushing

Excellent alternative when retrofitting the existing coke batteries

Effective & efficient capture of fumes during door opening and pushing sequence

Reduced air volume enables savings in Fabric Filter size

Compliance with Authority Rules for coke pushing emission control

Patented trav-l-vent technology for fume capturing



In house competence for effective fume capturing

Complete system with in-house technology

Movable TRAV-L-VENT fume capturing hood

Spark arrestor

Fabric Filter

Opacity increase during pushing sequence maximum 20%

Stack emission guarantee is 10 mg/Nm3



High efficiency dedusting - ALSTOM LKPB

Spark arrestors ensures reliable and safe operation

Safety dampers for unexpected process situation ( green push )

Fabric filter design based on ALSTOM world class technology

Pulse jet or reverse air fabric filters



Secondary ventilation



Secondary ventilation - number of references


28 Fabric Filter references

26 ESP references

Mixer and Converter secondary ventilation


Stock house ventilation


Material handling

20 Fabric filter references



Secondary ventilation - the solution

What is required to have a efficient de-dusting?Proper hood arrangement (lay out, placement, tilting/stationary)

Correct gas flow at each suction point

Total gas flow (mixing of the gases from various sources)

Control system - different process phases to be respected

Selection of de-dusting equipment - ESP or FF

Guarantees achieved at working areas and at stack

Satisfied customer


Tailor made hood arrangement for each single sources

Computerised Flow Dynamics (CFD) modelling used in hood design

Fabric Filter typically used for de-dusting

Low dust emission achieved (<10 mg/Nm3)

Secondary ventilation - ALSTOM s competence


Iron & Steel - references


Aceralia - Gijon - 2 ESPs for sinter primary gases 06 / 2004Arcelor - Fos sur Mer, France - NID for sinter primary gases 01 / 2004Mechel, Chelyabinsk, Russia - 4 ESPs for sinter primary gases 01 / 2004

Rautaruukki-Raahe, Finland - BOF and mixer secondary ventilation 05 / 2003

List of recent references for integrated steel plants:


Recent references - sinter primary

ARCELOR - Fos Sur Mer, France


Sinter primary gases

FDA/NID system with activated carbon and lime injection

Gas flow 800 000 m3/h

Emission guarantees

Dust 50 mg/Nm3

SOx 225 mg/Nm3

Dioxin 0,1 ng/Nm3

Start up May 2005

Recent references - Pelletising


COMPANHIA VALE DO RIO DOCE (CVRD)COMPANHIA VALE DO RIO DOCE (CVRD)

Location: São Luiz - MA, BrazilGas flow : 2 365 000 Nm3/hESP-type: 2 +1 ESP's, 3 fieldESP-control: EPIC IIStart up: 2002Inlet dust concentration: 1 500 mg/Nm3

Guaranteed emission: 70 mg/Nm3

Two ESPS for windboxes and one for hood.

Recent references - sinter primary

ARCELOR - Aceralia, Spain

Contract signed in June 2004

ESP for Sinter band A (375 ton/h)

Gas flow 800 000 m3/h

4 field ESP

Micro-pulsing energisation

Emission 50 mg/Nm3

Turn key installation

Start up June 2005



NovNoviiembembrere 20062006

Mini Mills at a Glance

In-house technology for complete (primary and secondary gases) air pollution control systems

Technology originated from Daneco and Fläkt

280 references within Electric Steel Shop / Mini Mill

more than 80 complete plant installed for E.A.F.

References at all continents

-- Electric steel shop / Mini Mill Electric steel shop / Mini Mill --

Mini Mills at a Glance

Recent product developments/improvements

Hot Quenching Tower - up flow design

Computerised Flow Dynamics (CFD) modelling for canopy hood

Fabric Filter cleaning valve design - patented OPTIPOW cleaning valve



Electric Steel Shop / Mini Mill

Electric Arc Furnace (E.A.F.) - primary & secondary emissions

Argon Oxygen De-carbonisation (A.O.D.) converters - primary & secondary emissions

Ladle Furnace (L.F.) - primary & secondary emissions

Scope of Business - Noise Proofing System:

Dog-house enclosure for E.A.F.Elephant-house enclosure for E.A.F.


E.A.F - primary and secondary de-dusting



Water Cooled Ducting (W.C.D.) - efficient cooling & energy production

High pressure design (12 bar) enables more efficient energy production

Combustion chamber is integrated to water cooled ducting

W.C.D. length is highly dependent on cooling method downstream of the ducting (draft coolers vs. hot quenching tower)

Cooling of primary gases


Water Cooled Ducting - Typical design features

Flue gas temperature (HQT downstream of WCD):Inlet: 1600 °COutlet: 900 °C

Flue gas temperature (Draft type Cooler downstream of WCD):Inlet: 1600 °COutlet: 500 °C

Water temperature (low pressure, 2-4 bar):Inlet: 50 °COutlet: 60 °C

Water temperature (low pressure, 8-10 bar):Inlet: 80 °COutlet: 110 °C




Hot Quenching Tower (H.Q.T.):



Hot Quenching Tower - design features


Two media nozzles

Typical flue gas temperaturesInlet: 900...1000 °COutlet: 250...350 °C

Design is optimised by using CFDtools

Both up-flow & down-flow design available

Up-flow design enables more efficient lay out >> savings in investment

Primary fumes quick cooling with the injection of finely atomised droplets of water. The high amount of the water evaporation heat allows the cooling of the fumes with a reduced amount of water.

Avoid the PCDD de-novo synthesis with the immediate cooling of the fumes below 250 °C just after the combustion chamber.

Connection of the primary fumes ducts to the secondary ventilation ducts just at short distance from the EAF, resulting in a more compact layout.

H.Q.T. - Advantages :



No need of installation of very long Water cooled Ducts, with the consequent reduction of the Water Treatment Plant Power consumption and running cost.

No need of Forced or Natural Draft Cooler reducing the system pressure losses (and consequently the main fan power consumption), and avoiding dust clogging in the cooler s tubes.

Very easy cleaning operations.

Rarely maintenance operation.

H.Q.T. vs. Draft coolers :



Typical design features for HQT :



Acc. di Verona 1Riva Group

(Italy)

Acc. di Verona 2Riva Group

(Italy)

Von Moss Stahl(Switzerland)

Acc. Stefana(Italy)

ALPA FranceRiva Group

(Italy)

ACIPco(USA)

GAS FLOW Nm3/h 130.000 130.000 100.000 200.000 110.000 190.000

PRESSUREAIR PEAK

Nm3/h 2.400 2.400 2.200 4.600 2.850 2.800

WATER PEAK m3/h 35 35 28 60 40 52

TEMPERAT.IN/OUT

°C 850-275 850-275 800-250 950-250 935-265 1.000-350

HQTDIAM./H

mm 2.300 / 8.350 2.300 / 8.350 3.000 / 7.500 4.000 / 13.000 3.000 / 12.000 2.500 / 40.000

RETENTIONTIME

sec 0.41 0.41 0.67 1.04 0.98 1.03

HQT TYPE Up Flow Up Flow Down Flow Down Flow Up FlowHorizontalFlow



Natural - and Forced Draft - Coolers

Natural draft cooler Forced draft cooler



Cleaning of the pipes essential important for efficient cooling and prevention of clogging

Typically used in processes with good scrap quality and stainless steel mills

Forced draft coolers requires smaller footprint compared to natural draft coolers.

Natural - and Forced Draft - Coolers

Secondary ventilation - canopy hood

Canopy hood - tailor made design

Optimised design for effective suction during all process sequences

CFD modelling based design

Proven technology with more than 70 installations world wide


Safe operation


Spark arrestors and safety dampers

Optimised pressured drop (400 - 700 Pa)

Efficient reduction of glowing particles

Enables safe operation for FF

Double safety dampers givesextra safety for FF operation

De-dusting


Fabric Filter - heart of the cleaning system

ALSTOM is the leading fabric filters supplier

More than 200 fabric filter installations in Iron&Steel industry

Both reverse air or pulse jet type fabric filter in product portfolio

Patented OPTIPOW cleaning valve design for pulse jet FF

EFFIC control system with broken bag detection

Excellent reliability and availability

Noise enclosures

Noise limits of 85 dB(A) in working areasNoise limits of 45 dB(A) in facilities boundaries

Noise enclosure SOLUTIONS that can:

retrofitted to existing meltshops, or

adapted to new plant layouts

RESPECT:


Gerdau-Cosigua, Brazil - EAF primary and secondary gases 11 / 2003Gerdau-Sao Paolo, Brazil - EAF primary and secondary gases 11 / 2003Outokumpu-Tornio, Finland - EAF primary and secondary gases 06 / 2003

Concast-EASRCO, Egypt - EAF primary and secondary gases 03 / 2003De Acero-Saltillo, Mexico - EAF primary and secondary gases 11 / 2002

List of recent references for Mini Mills:


Recent references

Recent references

Outokumpu Stainless Tornio - Finland EAF (150tons)

Water cooled ductingForced draft coolersCanopy hoodSpark arrestorFabric Filter

AOD (150 tons) Water cooled ductingForced draft coolersCanopy hoodSpark arrestorFabric Filter

Ladle furnaceCanopy hoodFabric Filter


Recent references

De Acero S.A. - Saltillo

EAF (55 tons) primary and secondary gasesRefurbishment of the existing flue gas treatmentStart up 2003 Delivery consisted:

New Hot Quenching tower - up-flow designAdditional fabric filter - pulse jet typeID fans


Recent references

Gerdau - Sao Paolo

EAF (100 tons) and LF primary and secondary gases

Complete flue gas handling system consisting Water Cooled ductingHot Quenching tower - up-flow designCanopy hood for capturing secondary fumesSpark arrestorReverse air type of fabric filter (700 000 m3/h)ID fans (2 * 1200 kW)Stack

Start up 2005


Recent references

Gerdau - Cosigua

EAF (170 tons) primary and secondary gases

Rebuilding of existing flue gas treatment Hot Quenching tower - up-flow design

Spark arrestorExtension of existing Reverse air type of fabric filter

Start up 2005


www.environment.power.alstom.com

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