revamping of eaf dedusting system to optimize off-gas...

KANTOR PUSATJl. Industri No. 5 P.O. Box 14 Cilegon, Banten 42435

Telepon : (+62 254) 392159, 392003 (Hunting)

Faksimili : (+62 254) 372246

KANTOR JAKARTAGedung Krakatau Steel, Lantai 4

Jl. Jend. Gatot Subroto Kav. 54 Jakarta Selatan 12950

Telepon : (+62 21) 5221255 (Hunting)Faksimili : (+62 21) 5200876, 5204208, 5200793

PABRIKCilegon – Cigading Plant Site, Banten 42435

Website : www.krakatausteel.com

Revamping of EAF Dedusting System to Optimize Off-Gas and

Dust Control System in PT. Krakatau Steel (Persero) Tbk.

SEAISI Conference 2017

Resorts World Sentosa Singapore

22 - 25 May 2017

Rio Arosyid Putra

Senior Specialist of Techno-economics

PT. Krakatau Steel (Persero), Tbk. - Indonesia

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OUTLINE

OVERVIEW OF COMPANY AND PLANT

PREVIOUS DEDUSTING SYSTEM CONDITION

REVAMPING: PROCESS & RESULT

CONCLUSION & RECOMMENDATION

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Location:

• Plant Site & Head Office : Cilegon

• Representative Office : Jakarta

Surabaya

Indonesian state-owned company in the field of strategic

industry and manufacture.

The largest integrated steel producer in Indonesia


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343 ha | PT KS45 ha | Cilegon City Gov.

Plant Site

Training Center

Head Office

(source: Official Website of Krakatau Steel, 2012)


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Long Product

Flat Product

3,150,000 tons/year

(HRC/P/S, CRC/S, WR)


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EXISTING DEDUSTING SYSTEM



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1st cooling stage

Primary dedusting

Secondary dedusting

2nd cooling stage


Built in 1992

Modification of Dedusting System in 1997 by Installing Force Draught Cooler.

In 2010, Installed 3 lines of Oxy-jet lance 3200 Nm3/h in each lance

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Dedusting System Trip (yellow colour)Dedusting System Trip Alarm (yellow colour)


Previous Situation

Over heating in Primary Hot Gas Line whichexceed 700oC

Temperature Hot Gas Line > 700oC will switchEAF operation off.

Operator would reduce the number of oxy-jetlance with only 2 lines which is the flow rateapprox. 1600 Nm3/h per each line (designed3200 Nm3/h).

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OVER VIEW OF COMPANY AND PLANT




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Objective:

1. Optimizing the performance of dedusting system

2. Supporting hot metal based operation in EAF

• Project Team:

1. Division of Technology Development

2. Division of Slab Steel Plant

3. Division of Workshop

• Mechanism:

Fully self-managed

no 3rd parties are involved

OVERVIEW OF REVAMPING

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REVAMPING PROCESS

Re-calculating dedusting system capabilities in terms of thermal load and off-gas volume produced by ‘new’ EAF

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REVAMPING SCHEDULE

No. Project Phase

2014 2015

6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11

1 Basic Design

2 Detail Design

3 Manufacturing

4 Erection

5Commissioning

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Final

Acceptance

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NO OBSTACLES REVAMPING SCOPE

1 The installation of new oxy-jet lance in EAF toantisipate Hot Metal usage lead to:

Expand heat absorber area and suction capacity, using:

a. Over heating at outlet Water Cooled Duct > 700 oC

a. Repair and Adding the section of water cooled duct and un-cooled duct.

b. Settlement dust increasing in the duct b. Install 2 units of Drop Out Box (DOB) and Recondition of Filter Plant existing with the new Filter Cleaning system.

c. Combustion Increase of CO gas at Water Cooled Duct

d. Off Gas Volume Increasec. Operating all ID Fan (4 Units) and preparing

1 ID Fan motor for stand by.

2 The condition of dedusting plant is not optimumas follows:

Upgrade (Extend):

a. Many leak in Water Cooled Duct a. Water Cooled Duct

b. Many cracks in Un-Cooled Duct b. Un-Cooled Duct

c. Control System condition is obsolete c. Automation Control & Piping System


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DESIGN CHANGE OF WATER COOLED DUCT

Modification of water cooled duct (WCD)

Install 2 units Drop Out Box

Modification of in-coming & out-going water header along with its sensors

New design of Steel structure to support new WCD

Girder


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INSTALL DROP OUT BOX (DOB)


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NEW DESIGN OF EAF DEDUSTING SYSTEM

REVAMPING RESULT

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REVAMPING RESULT

Water Cooled Duct

Un-cooled DuctDrop out Box

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NO PERFORMANCE TARGET RESULT

1. Inlet Force Draught Cooler, Max (0C) 530 371

2. Inlet to filter chamber, Max (0C) 120 83

3. Dust Content, Max (mg/m3) 50 5

4 Hot Gas Line Temperature (0C) 600 476

REVAMPING RESULT:

EQUIPMENT PERFORMANCE

0

50

100

150

200

250

300

350

400

450

10

:09

:53

11

:43

:23

13

:16

:54

14

:50

:25

16

:23

:56

17

:57

:27

19

:30

:58

21

:04

:29

22

:38

:00

00

:11

:31

01

:45

:02

03

:18

:33

04

:52

:04

06

:25

:34

07

:59

:05

09

:32

:36

11

:06

:07

12

:39

:38

T5361 (inlet uncooled)

T5362 (inlet mixing)

GIS5863 (%dec)

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1. Acceleration of knowledge transfer

2. Skill development of every personnel

3. Shorten the learning time

4. Minimize the competence gap

REVAMPING RESULT:

HUMAN CAPITAL ASPECTS

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OVER VIEW OF COMPANY AND PLANT




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CONCLUSION

1. Revamping of EAF Dedusting Plant could eliminate the

impact of raw material transformation in EAF (hot metal

material based operation)

2. By doing self-managed revamping, transfer of knowledge

was rapidly accelerated and the learning time could be

effectively shortened.

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THANK YOU

revamping of eaf dedusting system to optimize off-gas...

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