E N E R G Y   O P T I M I Z AT I O N

AT   E L E C T R I C   A R C   F U R N A C E S

INDEX

 Who Is CVS

 Steel Industry

 Steel Industry & Energy

 Why The Energy Efficiency Is

Important

 Classical Methods for Energy

Efficiency

 New Concepts for Energy

Efficiency 2
C O M PA N Y   P R O F I L E

CVS TURKEY
CVS EUROPE CVS MIDDLE EAST CVS CIS
Italy‐Udine Egypt‐Cario Ukraine‐Donetsk

FROM CONCEPT TO COMMISSIONING
Design
Manufacturing
Erection
Training

Consultancy
Innovation
Process Development

CVS POLAND CVS IRAN CVS INDIA CVS S.KOREA CVS SINGAPORE CVS INDONESIA CVS USA CVS GREECE CVS TRADE B.V.
Warsaw Tahran Pune Seoul Singapore Jakarta New York Athens Amsterdam
3
info@cvs.com.tr                          www.cvs.com.tr

C O M PA N Y   P R O F I L E

 CVS provides plants & equipments for minimills

(Meltshops & Rolling Mills), as well as “turn‐key”
solutions in this regard.

 CVS covers the complete design and

manufacturing activities for green‐field
green field projects
as well as revamping/upgrading of existing plants
and equipments.

 CVS manufactures spare parts & components for

Meltshops & Rolling Mills & Off
Off‐Gas
Gas Systems.
Systems

 CVS provides technical assistance and consulting

service to steel production.
4
C O M PA N Y   P R O F I L E

 CVS headquarter
q is located in the most sophisticated
p
industrial region of Turkey; Gebze (50 km to Istanbul
city center), close to many major ports.

 Our modern facilities consist of three integrated

major‐sized workshops equipped with post‐modern
machinery parks and three engineering buildings
summing up approx. 100,000 sqm.

 CVS workforce is formed by over than 750

specialized staff with a modern machinery park to
undertake
d t k even the th mostt challenging
h ll i projects.
j t

 More than 270 engineers and administrative

employees are involved in the design and
management of the projects. 5

ACTIVITIES

6
STEEL INDUSTRY

After crisis, World Iron & Steel Industry started to growing again.

In 2010, all over the world, more than 1 billion 400 million tons/year steel was produced,
and it will be increased each yyear as before crisis.

According to rapid growing up in recent years all over the world, new requirements and
new formations to answer these requirements are occured.

Steelmaking is always a growing sector and steelmakers are always asking for more
fl ibl and
flexible d more easy operation
ti for
f meltshop
lt h units.
it
7

STEEL INDUSTRY

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

847,670 850,345 904,053 969,992 1,069,082 1,146,686 1,251,196 1,351,289 1,329,123 1,211,461 1,413,596

The crisis of steel market was started in the end of 2008, as all other markets.

And it has been continued throughout the entire 2009.

In the end of 2009, the effects of crisis was began to pass. And again the market was
started to grow up.

But something was changed. Maybe the costs are not higher before crisis but profits are
lower.

Energy and scrap are the biggest cost of meltshops.

8
STEEL INDUSTRY

Today, investors worldwide are looking and waiting for new signals from steel market to
understand where to direct and dedicate their money, energy and resources for possible
alternative business. Because of uncertainty in the market, steelmakers are looking for
p
more flexible operation to catch the changing
g g market demands.

According to requirements of the market, steel production will be increased, and new
investment will be try to answer.

Competition will be even more difficult, and the steelmakers will look new concepts to
reduce
d th steelmaking
the t l ki costs.
t
9

STEEL INDUSTRY AND ENERGY

Why the energy efficiency is important?

Approximately 12% of energy produced all over the world is consumed at Iron & Steel
Industry.

So we can understand the importance of energy efficiency.

With the increasing of steel

of steel production, studies
production studies of to
of to reduce the energy consumption are
became important.

But 50% of consumed energy is loss

But, 50% of consumed is loss due to several reasons.
reasons

In the end of these studies, the recovered energy will be very high, and the costs can be 
reduced
d d with i h possible
ibl new concept investments.
i
10
STEEL INDUSTRY AND ENERGY

5 main input for meltshops with EAF

1. Scrap
2. Energy
3. Refractoryy
4. Ferro Alloys
5. Electrodes
To reduce the scrap cost is limited for steelmakers but they can recude energy
consupmtion themselves.

The scrap cost is determined by market. And request of steel production is increased
every day.

Based on this growing, coke, iron ore and scrap requested are increased so much and their
international costs will be higher than the past.

The difference between product and input price, is determined to the profit of
11
steelmakers.

STEEL INDUSTRY AND ENERGY

There are a lot of inputs and outputs of EAF.

p
But the most important and can be reduced one is electricityy energy.
gy

How can we reduced the electricity energy consupmtion?

With classical methods,

methods this is not advantage for the competition because of all important
competitors knows to use this energy input.

With new concepts, this can be created to make a difference if you can find the right
investments.
12
CHEMICAL ENERGY

In the EAF melting process the chemical energy is playing an important

role since production costs and productivity have to be always
improved.

It is now common practice to use between 30% and 40% of the total
energy input to the EAF being supplied through oxy‐fuel burners and
yg lancing.
oxygen g

Exothermic reactions are provided very

important energy input.

At EAF, while the energy inputs are calculated;

Total oxygen which blows from burners (burner
mode & jet mode) and lance manipulator, total
NG which blows from burners, total C which is
coming from with charge,
charge injection and scrap,
scrap
total removal elements are going into the
13
calculations.

CHEMICAL ENERGY

The Advantages of the CB system are:
‐ Operate the furnace with multipoint oxygen injection that allow a more 
intensive and/or efficient chemical energy utilization.
‐ Operate the furnace with multipoint carbon injection to better foam the 
slag.
‐ Minimise operation with slag door open reducing the energy losses via 
f
furnace off gas.
ff
‐ Avoid any manual lancing operations.
‐ High lifetime and reliability of the equipment.
‐ Full process automation.
Full process automation

The CB system has the following benefits on the furnace performance:
‐ Reduced electrical energy requirements, as less energy is lost in the off 
gases.
‐ Better energy and thermal balance inside the furnace.
‐ High flexibility and high efficiency on chemical energy utilisation.
14
CHEMICAL ENERGY

Along with the main target, the other reasons for using chemical energy for melting are:
‐ much greater flexibility of processes with regard to raw materials and energy availability
‐ increased productivity while simultaneously improved energy efficiency

The complete system installed on the furnace enables the following functions:
‐ Fuel utilization: the fuel burners are installed onto the cold spots in order to balance the total
energy input into the furnace on the basis of the process requirements.
‐ Steel bath refining: the multipoint oxygen injection allows for fast and homogeneous bath
decarburization and superheating.
‐ Slag foaming: the checking of the covering of the bath and the arc by a suitable management of
the carbon injection.
injection

yg ;
Burner oxygen;
‐ Burner fuel (Natural Gas, LPG, CH4, etc.);
‐ Lance oxygen;
‐ Carbon injection.

15

CHEMICAL ENERGY

To reduce the power on time, the electrical energy input to the furnace must be rather aggressive.
The correct power program must be used and is designed to balance both electrical and chemical
(burner and lance) power inputs. In the early stages of melting a short arc is selected to avoid
excessive damage to the roof panels from arc flare. This slight reduction in the initial power is
however compensated for by the CB burner‐injector units which are fired very quickly during initial
arcing and maximize the energy input to the cold scrap.

Slag foaming
Sl f i isi extremely
t l important
i t t if an aggressive
i arc is
i to
t be
b maintained
i t i d throughout
th h t the
th heat.
h t AsA
the scrap level reduces in the furnace and flat bath conditions are approached the height of the
foaming slag must be increased to completely submerge the arc and prevent damage to the water
cooled panels.
panels

16
CHEMICAL ENERGY

REMOVAL OF ELEMENTS C, C Si and Mn

All of the heats of formation of the oxides are exothermic so oxidation of the elements actually
helps to raise the temperature of the bath. In addition the formation of CO helps to stir the bath and
homogenise it whilst promoting further slag slag‐metal
metal reactions.
reactions The heats of formation can be
calculated if the Wt% of the element in the molten bath is known.

2Al(l) + 2/3O2(g) = Al2O3 
() / (g) ΔHR = ‐402  Kcal/mol
/
Si(l) + O2(g) = SiO2  ΔHR = ‐226  Kcal/mol
Mn(l) + 1/2O2(g) = MnO ΔHR = ‐97.45  Kcal/mol
(g) (g)
2C + O2(g) = 2CO (g)  ΔHR = ‐28  Kcal/mol
2Fe + O2(g) = 2FeO  ΔHR = ‐63.5 Kcal/mol

Carbon alone is not enough to create a foaming slag. Often the chemistry of the slag itself is 
ignored. The CO bubbles generated in the bath from direct oxidation of carbon, or those created in 
the slag by mixing C and O or reducing FeO will all escape from the slag very quickly unless the slag 
composition is correct.
17

CHEMICAL ENERGY

The system has below mentioned results:
y

‐ Increase of production

‐ Reduction of production cost

‐ Reduction of electric energy
Reduction of electric energy

‐ Reduction of tap to tap time

‐ Reduction of electrode consumption

‐ Better efficiency of the carbon

‐ Better homogenization of the melt
g
* According to temperature and flowing rate 
these values can be changed
‐ Low investment cost 18
NEW CONCEPTS

Scrap Pre‐Heating Systems

One Charge EAF Some new technologies and concepts

are developled by providers of steel
making plants.
EPC System

Which one is the right investment for you?

CVS has a new concepts and advises to reduce

the energy consumption of EAF.

19

S C R A P   P R E ‐ H E AT I N G   S Y S T E M

15 – 20 % of contained
15 20 % of contained energy as 100 ‐
as 100 150kwh/t in EAF during
150kwh/t in EAF during the oparation, is gone
oparation is gone out via duct
emissions.

CVS scrap pre‐heater is a system which utilizes this

heat energy to heat scrap in a bucket before charged
into the EAF and thus contributes towards to energy
saving.
i

Evacuated gas from the EAF is flowed to the

combustion chamber, and via the second out way
with another duct pipes, hot gas is flowed to the
scrap buckets, gone into bucket to heat scraps and
after that gone out from bottom of scrap bucket and
via duct pipes, mentioned gases are gone to the FTP
after ggives existingg heats to the scraps.
p

20
S C R A P   P R E ‐ H E AT I N G   S Y S T E M

Preheating is burned by mixing with the gas from

the EAF. This enables to eliminate an air pollution
after dust collector.

By provision of preheating fan, existing fume

treatment plant can employ the scrap pre‐heater
without modification.

As the system is fully automatically operated, this

system does not require additional worker.
EAF operation
ti willill nott be
b interrupted
i t t d even though
th h
the preheating system run into a trouble.

Recycling method of preheating system can be controlled separately from dust collector system.

Proper adjustment
P dj t t off the
th preheating
h ti temperature
t t prevents
t the
th scrap bucket
b k t the
th scrap bucket
b k t
from being deformed.
21

S C R A P   P R E ‐ H E AT I N G   S Y S T E M

Specifications
Scrap Preheating system for improved efficiency of Meltshop
Easy Solution
Low Investment Cost
Better Operation Main Profit: 
Adaptable for Existing Automation Preheated scrap average temperature is 
Maintenance Friendly between 150°C ‐ 200°C 
The amount of energy saving is 20 –
h f i i 30 kwh/ton 
k h/
in practice.

Preheating system:
P h ti t
‐ Inlet temperature of preheater: approx. 800ºC – 200º C

‐ Outlet tempearture
Outlet tempearture of preheater: approx. 250
of preheater: approx 250º C –
C – 50
50º C

‐ Temperature of preheated scrap: approx. 400º C – 100º C

‐ Temperature at combustion chamber inlet widely varies between 1200º C to 300º C according to 

the time and conditions of the steelmaking stages. 22
ONE CHARGE EAF

23

ONE CHARGE EAF

Our invention makes possible the continuous melting of ferrous materials such as sponge iron,
iron scrap
iron or iron ore in an electric arc furnace so that the electric arc is never turned off nor is the power
ever reduced.
reduced

Our invention comprises an electric arc furnace for continuous

charging of ferrous materials and semi continuous tapping of
molten steel when it is adequately refined.

24
ONE CHARGE EAF

Most modern furnaces are designed g to operate

p with a minimum of back‐charges.g This is
advantageous because charging is a dead‐time where the furnace does not have power on and
therefore is not melting. Minimizing these dead times helps to maximize the productivity of the
furnace. In addition, energy is lost every time when the furnace roof is opened.
This can amount to 10–20 kWh/ton for each occurrence.

Most operations aim for 2 to 3 buckets of scrap per

heat and will attempt to blend their scrap to meet
this requirement.
requirement Our invention achieve a single
bucket charge.

25

ONE CHARGE EAF

Constant flat bath allows for high

g electrical efficiencyy if a ggood foamyy slagg is maintained !
Otherwise ‐ damage to refractory, accelerated delta wear, increased electrode
consumption, decreased yield, increased power consumption, increased wear on oxygen
lance.
lance

Specific Objectives of New Process
‐ Lower specific capital costs
‐ Lower primary energy consumption
‐ High productivity/low conversion cost
g p y
‐ Flexibility in choice of feed materials
‐ Lower T‐T‐T closer
‐ Maintain maximum process flexibility
Maintain maximum process flexibility
‐ Increase product quality while maintaining cost competitiveness
‐ More environmentally friendly and meet environmental requirements at minimum cost
‐ Maximizing power input to the EAF by using a combination of energy sources
Maximizing power input to the EAF by using a combination of energy sources
‐ Optimized energy use and electrical power supply optimized to minimize losses
26
ONE CHARGE EAF

This invention offers many features that are not available in the present art: 

‐ the charge is continuous and several types of materials can be charged simultaneously;
‐ the required melting time is reduced because the furnace works continuously; 
‐ heat and emissions released into the environment are reduced because the furnace always works 
with closed cover; 
‐ all motions required for charging, melting, refining and tapping the steel are automated;
‐ the furnace tilting motion enables the steel to be refined during the melting process thus assuring 
a precise control of the steel temperature and composition;
‐ dust dispersion is reduced and, therefore, transformation yield is improved; 
d d d d d h f f ld d
‐ Modern operations aim for a tap‐to‐tap time of less than 45‐50 minutes. We aim for achieving tap‐
t t ti
to‐tap times of 40
f 40 to 45
t 45 minutes. 
i t

27

ONE CHARGE EAF

Low Powered EAF UHP  EAF CVS EAF

Inputs
p /ton kWh % Inputs /ton kWh % Inputs /ton kWh %
Electrical 580 82 Electrical 420 65 Electrical 38
380
0 65
Chemical 125 18 Chemical 190 30 Chemical 190 30
Total 705 100
Burner 30 5 Burner 30 5
Outputs
Total 640 100 Total 600 100
Steel 365 52
Slag 80 11 Outputs Outputs
Electrical
l i l 90 13 Steel 365 58 Steel 365 58
Misc 80 11 Slag 65 10 Slag 65 10
Offgas 50 7 Misc 15 2 Misc 10        2
0        2
C Water
C Water 40 6 Offgas 130 20 Offgas 100 20
C Water 65 10 C Water 60     10
60     10

28
E P C :   E N V I R O N M E N TA L   P R E H E AT I N G   &
CONTINUOUS CHARGING SYSTEM

29

EPC SYSTEM

CVS MAKINA has a commercial cooperation with KR Tec company which has developed a
New Generation concept in Arc Furnace Steelmaking, ENVIRONMENTAL PREHEATING &
CONTINUOUS CHARGING SYSTEM (EPC).

Idea behind the challenge is to recover the heat lost to FTP system by the application of
Scrap Preheating.

The EPC System combines the advantages of the

preheating efficiency of the chamber and the
continuous scrap feeding.
feeding

The EPC System is a new generation of economical

arc furnace.
furnace

EPC system overcomes all the missing items of the

existing Preheating system.

30
EPC SYSTEM

One of the issues of the EPC System is to charge the scrap independent of the electric arc furnace
taken into consideration the environmental aspects.

The EPC System is installed beside the EAF and the preheated scrap can be charged continuously by
the telescopic feeder system in the melting chamber during Power On.

Even during charging of the scrap basket into the EPC System, the system is always airtight and a
small amount of dust can only escape. Furthermore, the design has been considerably simplified to
increase the reliability and the profitability of the investment, reducing the ROI by less than 12
months.

31

E P C   S Y S T E M :   A D VA N TA G E S

ENERGY SAVING
ENERGY SAVING
The EPC reduces the electric energy consumption by approx. 80‐100 kWh/t compared to the 
conventional EAF. 

INDEPENDENT SCRAP CHARGING
g g p p p y p
Charging of the scrap basket is done with power‐on and independently from the furnace operation. 
This improves the operation and reduce the Power off time 

HIGHER PRODUCTIVITY
Due to shorter power‐on and power‐off times. The productivity of the furnace can be increased by
min. 20 % compared to the conventional EAF.

HIGHER RETURN ON INVESTMENT
Th EPC System
The S t f t
features l
lower conversion
i costt due
d to t the
th preheating
h ti effect.
ff t Furthermore
F th hi h
higher
productivity because of less power‐on and power‐off are assured.
32
E P C   S Y S T E M :   R E S P E C T   T O   N AT U R E

MINIMUM DUST EMMISION
During charging procedure the system/pre‐heating chamber is always in airtight situation which 
reflects a minimum of pollution in the meltshop.

LOW FTP CAPACITY REQUIREMENT
Fume Treatment System capacity is reduced thank to the completely closed operation and flat bath 
condition.

LOW DOWNTIMES & MAINTENANCE
No critical mechanical parts such as fingers, conveyors, water cooling which cause unforeseen 
stoppages and maintenance.
t d i t

ADAPTABLE TO CONVENTIONAL METHOD
Operation can be changed immediately to Conventional method by opening of the off gas bypass 
Operation can be changed immediately to Conventional method by opening of the off gas ‐ bypass
flap.

LESS FLICKER
LESS FLICKER
Related to the flat bath operation, preheated scrap and the constant energy input, a reduced flicker 
and less noise generation will be achieved. 33

EPC SYSTEM: BENEFITS REGARDING 
ENVIRONMENT

 Charging with airtight system

 Minimum fume during scrap charging
Mi i f d i h i

 Cleaner working area
g

 Min. 30% less off gas

 Min. 30 % less dust at the filter

 Less noise  (melting of preheated scrap)

 Respect of most environmental standards
34
E P C   S Y S T E M :   F E AT U R E S

Flat bath operation

Controlled scrap quantity input through
telescopic feeder system

Charging during power on

Preheating temperature controlled by PLC

Minimized off gas volume related to airtight 
system

35

EPC SYSTEM

The scrap basket will be charged into a drawer of the EPC system which is in waiting position.

While this position the front wall of the drawer is closing the preheating chamber and the
melting process in the EAF and preheating doesn`t have to be interrupted.

After filling of the drawer by the scrap basket a slide gate on top of the EPC System will be closed.

Than the drawer will be forwarded by hydraulic cylinders to the preheating chamber and the
scrap falls smoothly inside the pre‐heating chamber where it will be preheated.

If the drawer is in front position, the back wall of it, is closing to the pre‐heating chamber.

A special design of the off gas duct together with a water cooled regulation flap allows to control
the preheating effect in the pre‐heating chamber.

36
EPC CHARGING HOPPER IN

CHARGING POSITION PREHEATING POSITION

37

EPC TELESCOPIC FEEDER IN

STA RT P O S I T I O N FRONT POSITION

38
EPC SYSTEM: MAIN COMPONENTS

CLOSING SLIDE CHARGING

B Y PA S S S Y S T E M G AT E
OFF GAS FUNNEL

OFF GAS
R E G U L AT I O N
FLAP CHARGING
HOPPER

TELESCOPIC
SCRAP
FEEDER
SYSTEM

EPC SYSTEM
T R AV E L L I N G
FRAME

39

EPC SYSTEM 3D VIEWS

40
EPC SYSTEM 3D VIEWS

41

PROCESS STEPS OF EPC

Refining phase of EAF

‐Preheating of 1st bucket of next heat in pre‐heating chamber
‐Charging of next bucket into charging hopper 42
PROCESS STEPS OF EPC

Charging of Preheating Chamber

‐Moving of charging hopper into pre‐heating chamber
‐Preheating of 2nd  bucket of next heat in pre‐heating chamber
‐Off gas flap of by pass system closed 43

PROCESS STEPS OF EPC

Preheating inside EPC

‐Start feeding of preheated scrap after tapping
‐Pre‐heating chamber half empty hopper can move backward to waiting  44
position
PROCESS STEPS OF EPC

Preheating inside EPC

‐Scrap bucket in waiting position
S b k ti iti iti
‐Continuous feeding of scrap during power on
‐Control of preheating scrap temperature with by‐pass regulation flap 45

PROCESS STEPS OF EPC

Charging of Upper Hopper EPC

‐Start feeding of preheated scrap
‐Opening of sliding gate on top
46
‐Charging of next bucket into charging hopper
PROCESS STEPS OF EPC

Parking Position of EPC

‐EPC system is moving backward on wheel mechanism underneath only for

47
maintenance purpose

O P E R AT I O N A L   C Y C L E   D I A G R A M
WITH EPC
E A F C A PA C I T Y 100 TON
T R A N S F O R M E R C A PA C I T Y 1 0 0 M VA
700

600
LIQUID STEEL

500

SCRAP WEIGHT
400 IN FIRST
CHAMBER

300 SCRAP TEMP IN

FIRST CHAMBER

200

SCRAP WEIGHT
IN SECOND
100 CHAMBER

-
0 5 10 15 20 25 30 37 42 47 52
48
LIQUID STEEL LEVEL DURING CYCLE
WITH EPC
140

E A F C A PA C I T Y
120 100 TON

TRANSFORMER
100 C A PA C I T Y
1 0 0 M VA

80
LIQUID STEEL

60

SCRAP WEIGHT IN
FIRST CHAMBER
40

SCRAP WEIGHT IN
SECOND
REPARATI

PREEPARATION
20 CHAMBER
APPING
1 HEAT CYCLE
PR

TA

-
0 5 10 15 20 25 30 37 42 47 52
49

C O M PA R I S O N   O F   P R O D U C T I V I T Y

PRODUCTION DIFFERENCE
EPC - EAF CONVENTIONAL EAF
Tra n s f o r m e r M VA 100 100
Ta p - w e i g h t t 100 100
Net working hours h/y 7.200 7.200
Power-on Time min 32 36
Power-off time min 6 11
Ta p - t o - Ta p - t i m e min 38 47
Production/hour t/h 157,89 127,66
Production/year t/y 1.136.842 919.149
Difference t/y 217.693

20 % PRODUCTIVITY INCREASE
WITH EPC SYSTEM
(100 TON – 100 MVA FURNACE)
50
C O M PA R I S O N   O F   O P E R AT I O N A L   C O S T

O P E R AT I O N A L C O S T D I F F E R E N C E
CONVENTIONAL
Unit price EPC- EAF EAF
Unit EUR Consumption EUR/t Consumption EUR/t

Electrical energy KWh/t 0,06 300,0 18,0 380,0 22,8

Oxygen Nm³/t 0,20 38,0 7,6 38,0 7,6

Electrodes kg/t 4,00 1,3 5,2 1,6 6,4

Fuel Nm³/t 0,20 3,0 0,6 6,0 1,2

Charged carbon kg/t 0,20 - - 7,0 1,4

Injected carbon kg/t 0,20 15,0 3,0 8,0 1,6

Scrap % 0,30 0,89 337,1 0,89 337,1

Dust removal kg/t 0,20 12,0 2,4 18,0 3,6

Lime kg/t 0,10 38,0 3,8 38,0 3,8

T O TA L 377,7 385,5
Savings EUR/t 7,8

8 €/T SAVING IN OPERATIONAL COST WITH EPC SYSTEM
51
(100 TON – 100 MVA FURNACE)

C O M PA R I S O N   O F   C O N V E R S I O N   C O S T S

EPC - EAF CONVENTIONAL EAF

Annual Production t/y 1.136.842 919.149
Operational Cost EUR/t 378 385
Sales Price EUR/t 420 420
C A L C U L AT I O N
Annual Operational
Cost EUR/y -429.360.993 -354.312.293
Annual Fixed Cost EUR/y -30.000.000 -30.000.000
To t a l C o s t f o r
Production EUR/y -459.360.993 -384.312.293
Sales Revenue EUR/y 477.473.684 386.042.553
Annual Profit EUR/y 1 8 . 11 2 . 6 9 1 1.730.261
Saving with EPC EUR/y 16.382.430

AROUND 16 MILLION EUR ANNUAL SAVING 
WITH EPC SYSTEM
WITH EPC SYSTEM
(100 TON – 100 MVA FURNACE) 52
C O M PA R I S O N   O F   R I O

R O I C O M PA R I S O N
30

25

20

15

ROI FOR
Million Euro

10
EPC-EAF
EPC - EAF

5 CONV EAF

-
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

-5
ROI FOR CONV-
EAF
-10

-15
Time (month)
53

EPC SYSTEM POWER FLUCTIONS

VOLTAGE, CURRENT AND POWER FLUCTUATIONS;
BEFORE AND AFTER SCRAP PREHEATING

54
R E S U LT S

Investment Costs of New Concepts

Advantages Which Are More Than Competitors

CVS provides tailor‐made different alternative solutions according to all your requests and
requirements, as below;

‐ Layout
‐ Target
T off Investment
I
‐ Process Conditions
‐ Budget

55

Yo u r   O n e ‐ S t o p
Solution Provider for
Meltshops & Rolling Mills

56
R E F E R E N C E S   ‐ M E LT S H O P S

Capacity
Year of start‐
Year of start
Customer Country Location Product Production units
(tpy) up

ABINSK ELECTROMET. PLANT Russia Abinsk 1.300.000 Billets Complete Meltshop 2012

ENERGOMASSPETSTAL Ukrain Kramatorsk 600.000 Ingot Complete Meltshop 2011

TAYBAH STEEL CO. Egypt Al Mansura 450.000 Billets Complete Meltshop 2011

ZELJEZARA NIKSIC AD. Montenegro Niksic 500.000 Billets

EAF, FTP, WTP, AUX 2010

TOSCELIK A.S. Turkey Iskenderun 1.400.000 Billets&Slab Complete Meltshop 2009

KHAZAR BILLET CO. Iran Rasht 800.000 Billets EAF, LF, FTP, AUX 2008

CONSOLITED JORDANIAN STEEL CO. Jordan Amman 200.000 Billets Complete Meltshop 2007

UNITED IRON & STEEL MGF. CO. Jordan Amman 250.000 Billets EAF, LF, CCM, FTP 2007

NURSAN METALURJI A S
NURSAN METALURJI A.S. Turkey Iskenderun 700 000
700.000 Billets Complete Meltshop
Complete Meltshop 2006

CER CELIK A.S. Turkey Izmir 500.000 Billets EAF, LF, FTP, AUX 2006

57

REFERENCES ‐ EAF

Tap Capacity Shell dia. Transformer Year of 

Customer Country Location
(tons) (mm) (MVA) start‐up
ABINSK ELECTROMET. PLANT Russia Abinsk 130 7.200 130 2012
ENERGOMASSPETSTAL Ukrain Kramatorsk 70 5.300 52 2011
TAYBAH STEEL CO. Egypt Al Mansura 60 5.300 52 2011
ZELJEZARA NIKSIC AD
ZELJEZARA NIKSIC AD. Montenegro Niksic 65 5 300
5.300 52 2010
DHT METAL  Azerbaıjan Baku 30 3.900 25 2009
UNITED IRON & STEEL MFG CO. Jordan Amman 50 5.000 45 2009
TOSCELIK A.S. Turkey Iskenderun 155 7.300 130 2009
KHAZAR BILLET CO.
KHAZAR BILLET CO Iran Rasht 100 6.100
6 100 78 2008
NURSAN METALURJI A.S. Turkey Iskenderun 130 7.200 135 2008
SOCIETE UNIVERS ACIER (SET 2) Morocco Casablanca 50 4.800 50 2008
SOCIETE UNIVERS ACIER (SET 1) Morocco Casablanca 50 4.800 50 2008
DETAL LTD.
DETAL LTD. Azerbaijan Baku 85 6.000 80 2008
YESILYURT DEMIR CELIK A.S. Turkey Samsun 90 6.100 100 2008
COJSCO Jordan Amman 35 4.500 45 2007
IZMIR DEMIR CELIK A.S. Turkey Izmir 130 6.500 120 2007
BAKU POLAT DOKME LTD.
BAKU POLAT DOKME LTD. Azerbaijan Baku 25 3.900 20 2007
AL HADDAD STEEL CO. Palestine Hibron 12 3.200 5 2007
CER CELIK A.S. Turkey Izmir 45 5.000 45 2007
NURSAN METALURJI A.S. Turkey Iskenderun 75 5.500 100 2006
YESILYURT DEMIR CELIK A.S.
YESILYURT DEMIR CELIK A.S. Turkey Samsun 60 5.300 50 2006
EKINCILER A.S. Turkey Iskenderun 90 6.100 85 2005
KAPTAN DEMIR CELIK A.S. Turkey Istanbul 120 6.300 120 2005
JORDAN IRON & STEEL CO. Jordan Amman 13,5 3.100 7 58
2005
R E F E R E N C E S   ‐ S E C O N D A R Y   M E TA L U R G Y

Capacity Transformer Year of 

Customer Country Location
(tons) (MVA) start up
start‐up
ABINSK ELECTROMET. PLANT Russia Abinsk 130 24 2012
WONKANG METAL CO. S.Korea Seoul 16 VD/VOD 2011
CEMTAS Turkey Bursa 30 5 2011
ORUMIEH STEEL
ORUMIEH STEEL I
Iran O
Orumieh
i h 25 5 2011
ENERGOMASSPETSAL Ukrain Kramatorsk 140 24 2011
TAYBAH STEEL CO. Egypt Al Mansura 60 10 2011
KUMAS MANYEZIT (SET 2) Turkey Kutahya Producing Fused Mgo 2010
KARDEMIR A.S. Turkey Karabuk 120 22 2009
TOSCELIK A.S. Turkey Iskenderun 155 24 2009
KUMAS MANYEZIT (SET 1) Turkey Kutahya Producing Fused Mgo 2008
DETAL LTD
DETAL LTD. Azerbaijan Baku 85 16 2008
KHAZAR BILLET CO. Iran Rasht 100 20 2008
YESILYURT DEMIR CELIK A.S. Turkey Samsun 90 16 2007
COJSCO Jordan Amman 35 8 2007
UNITED IRON & STEEL MGF CO. Jordan Amman 50 12 2007
COCSCO Jordan Zarqa 35 8 2007
JORDAN IRON & STEEL CO. Jordan Amman 15 5 2006
COJSCO Jordan Amman 45 8 2006
CER METAL A.S. Turkey Izmir 45 12 2006
NURSAN METALURJI A.S. Turkey Iskenderun 100 18 2005
KROMAN CELIK A.S. Turkey Kocaeli 100 18 199859

REFERENCES ‐ CCM

Sections
Casting Nr. of 
Nr of Year of 
Year of
Customer Country Location Product
Radius Strands start‐up
(mm)

ABINSK ELECTROMET. PLANT Russia Abinsk 9 m 6 Square billets 130 ‐ 200 2011

ARCELOR MITTAL TEMIRTAU Kazakhstan Temirtau 9m 6 Square billets 100 ‐ 200 2011

TAYBAH STEEL CO. Egypt Al Mansura 6 m 4 Square billets 100 ‐ 160 2011

ZELJEZARA NIKSIC AD. Montenegro Niksic 5 m 4 Square billets 100 ‐ 140 2010

TOSCELIK A.S. Turkey Iskenderun 9 m 6 Square billets 130 ‐ 200 2009

KHAZAR BILLET CO. Iran Rasht 6 m 6 Square billets 100 ‐ 160 2008

Square & round 
YESILYURT DEMIR CELIK A.S. Turkey Samsun 8 m 6 100 ‐ 200 2007
billets

COJSCO Jordan
d Amman 6 m 3 Square billets
b ll 100 ‐ 160 2006

CER METAL A.S. Turkey Izmir 5 m 4 Square billets 140 2006

CER METAL A S
CER METAL A.S. Turkey Izmir 5m
5 m 3 Square billets
Square billets 200 2006

NURSAN METALURJI A.S. Turkey Iskenderun 5 m 6 Square billets 100 ‐ 150 2005

60
REFERENCES ‐ FTP

Plant Capacity Year of 

Customer Country Location Technology
(m3/h) start‐up
ABINSK ELECTROMET. PLANT Russia Abinsk 2.300.000 Pulse‐jet FF 2012
JSC DNEPROSPETSSTAL Ukraine Zaporozhye 1.200.000 Pulse‐jet FF 2011
ENERGOMASSPETSTAL Ukraine Kramatorsk 1 200 000
1.200.000 Pulse jet FF
Pulse‐jet FF 2011
TAYBAH STEEL CO. Egypt Al Mansura 600.000 Pulse‐jet FF 2011
ZELJEZARA NIKSIC AD. Montenegro Niksic 1.200.000 Pulse‐jet FF 2010
DHT METAL  Azerbaijan
j Baku 650.000 Pulse‐jet FF
j 2009
BILECIK DEMIR CELIK Turkey Bilecik 500.000 Pulse‐jet FF 2009
TOSCELIK A.S. Turkey Iskenderun 2.300.000 Pulse‐jet FF 2009
KARDEMIR A.S. Turkey Karabük 220.000 Pulse‐jet FF 2009
SOCIETE UNIVERS ACIER Morocco Casablanca 2.350.000 Pulse‐jet FF 2009
ALEZZ STEEL AL DEKHILIA (Set 2) Egypt Alexandria 1.400.000 Reverse‐air FF 2009
ALEZZ STEEL AL DEKHILIA (Set 1) Egypt Alexandria 1.400.000 Reverse‐air FF 2009
COJSCO Jordan Amman 600.000 Pulse‐jet FF 2006
YESILYURT DEMIR CELIK A.S. Turkey Samsun 2.000.000 Pulse‐jet FF 2006
CER CELIK ENDUSTRISI A.S. Turkey Izmir 1.200.000 Pulse‐jet FF 2006
NURSAN METALURJI A.S. Turkey Iskenderun 1.000.000 Pulse‐jet FF 2005
CER METAL A.S. Turkey Izmir 1.500.000 Pulse‐jet FF 2005
61

REFERENCES ‐ MHS

Customer Country Location Products

ABINSK ELECTROMET. PLANT Russia Abinsk MHS for EAF,Scrap bucket, LF

CMC SISAK Crotia Sisak MHS for EAF,Scrap bucket, LF

KARDEMIR A.S. Turkey Karabuk MHS for LF

TOSCELIK A.S. Turkey Iskenderun MHS for EAF,Scrap bucket, LF

TAYBAH STEEL CO. Egypt Al Mansura MHS for EAF, LF

COJSCO Jordan Amman MHS for EAF,Scrap bucket, LF

KROMAN  Turkey Kocaeli MHS for LF

62
REFERENCES ‐ OFF GAS SYSTEMS

C
Customer C
Country Location
i Products
d

ISDEMIR Turkey Iskenderun Skirt & Moveable Hood & Fixed Hood

THYSSEN‐KRUPP AST Italy Terni WC hood for AOD

ARCELOR MITTAL ANNABA Algeria
g Annaba SMS 1 ‐ Moveable Hood & Fixed Hood

ARCELOR MITTAL ANNABA Algeria Annaba SMS 2‐ Skirt & Movable Hood & Fixed Hood

SALZGITTER FLACHSTAHL Germany Dusseldorf Off Gas Stack Cover

63

R E F E R E N C E S   ‐ S PA R E   PA R T S
Customer Country Customer Country Customer Country
ACCIAIERIE VALBRUNA Italy EKINCILER DEMIR CELIK Turkey MITTAL SKOPJE
MITTAL SKOPJE Macedonia
AL RAJHI Saudi Arabia ELECTROSTAL Ukraine MOBARAKEH STEEL Iran
AL TUWAIRQI Saudi Arabia ELWOOD STEEL Belgium NATIONAL STEEL Saudi Arabia
ALL EZZ GROUP Egypt ENGINEERING STEEL 
Belgium NOVOROS METALL LTD. Russia
ALSTOM POWER Italy BELGIUM
NURSAN METALURJI AS
NURSAN METALURJI AS Turkey
AMK ALCHEVSK Ukraine ERVIN AMASTEEL Belgium
QATAR STEEL Qatar
ARCELOR MITTAL RUHRORT Germany ETEAM Italy
REVYAKINO Russia
ARCELOR MITTAL TEMIRTAU Kazakhstan FERRIERE NORD Italy
ARCELORMITTAL  SALZGITTER FLACHSTAHL Germany
France FOLDER Denmark
DUNKERQUE SHARQ SOHAR Oman
GERLAFINGEN Switzerland
ARCELORMITTAL HAMBURG Germany SIDENOR SA Greece
GORKY STEEL Russia
ARCELORMITTAL SKOPJE Macedonia SIDERURGICA BALBOA Spain
G‐STEEL Thailand
ARCOSTEEL Egypt SIVAS DEMIR CELIK Turkey
HALYVOURGIA THESSALIAS SA Greece
HALYVOURGIA THESSALIAS SA
BAKU STEEL Azerbaijan SOHAR STEEL Oman
HALYVOURGIKI Greece
BENTELER Germany SONASID Morocco
INDUSTRIAS NACIONALES Dominican Rep.
Bosnia SOVEL Greece
BH STEEL IZMIR DEMIR CELIK Turkey
Herzegovina
SUEZ STEEL gyp
Egypt
CARINOX Belgium JORDAN IRON & STEEL CO
JORDAN IRON & STEEL CO. J d
Jordan
SWISS STEEL Suisse
CEMTAS Turkey KAPTAN DEMIR CELIK Turkey
THAME STEEL United Kingdom
CER METAL AS Turkey KARABUK DEMIR CELIK Turkey
TIMKEN USA
CHARTER STEEL USA KOMOTEK Bulgaria
TOSYALI HOLDING
TOSYALI HOLDING Turkey
CMC SISAK Croatia KREMIKOVSKI Bulgaria
UNITED IRON & STEEL MGF. CO. Jordan
COJSCO Jordan KURUM STEEL Albania
YESILYURT Turkey
CORUS Holland MAKEEVKA STEEL WORKS Ukraine 64
ZELJEZARA NIKSIC AD Montenegro
DUFERCO Belgium MED STEEL  Syria