Dedusting Systems for Blast Furnaces and Steelworks Brochure

6315eDuring hot metal productionas well as in steel works andin foundries emissions arise atvery different locations. Theseemissions must be reliablycaptured and filtered.Besides intensive filtering, efficiency plays a keyrole. The emissions must be extracted with as littlefalse air as possible. Moreover, the pressure loss inthe duct system must be minimized.Both the exhaust and the air transport in the ductsystem of KÜTTNER dedusting plants are sys-tematically optimized in terms of flow technology.This markedly reduces the operating costs of filterplants. The KÜTTNER systems only exhaust air thatneeds cleaning – clean ambient air is not “unne-cessarily” filtered. This improves the capturing effi-ciency, while maintaining the volumetric flow con-stant, or it reduces the volumetric flow, while main-taining the same level of cleaning efficiency.The engineering company, which was foun-ded in 1949 by Dr. Carl Küttner, has evolvedinto a group of companies active worldwidein engineering turn-key process, melting andconveying plants for the metals producingand processing industry.The “dedusting technology” division hasevolved from the engineering of ancillaryplants for “processing technology” applicati-ons. Through its intensive engagement withflow simulation issues, KÜTTNER has becomea highly competent partner also in the con-struction of large-scale dedusting facilities.The service range comprises the planning,design, delivery, assembly as well as commis-sioning of plants complete with control anddata processing systems.The KÜTTNER Group today has a worldwideworkforce of 400. It is represented in theinternational markets through a network ofagents and affiliated companies. The majori-ty of its owners actively work in the company.OPTIMIZED EXTRACTION OF EMISSIONSACHIEVES COST ADVANTAGESKÜTTNER GMBH & CO. KGWhen dealingwith largeexhaust air volu-mes, only a detai-led flow-technolo-gical investigationcan guarantee anoptimal design ofall componentsvoestalpineStahl GmbH,LinzBlast furnace 4-6Cast house withextraction equip-ment, filter plantand blowerhouse5,5 mDEDUSTING SYSTEMSfor Blast Furnaces and Steel WorksEfficient Exhaust GasExtractionReduction of Filter CostsEnergy SavingsEco-Friendly Operationinfo@kuettner.dewww.kuettner.deKüttner GmbH & Co. KGBismarckstr. 67 · 45128 EssenPhone +49 (0) 201 72 93-0Fax +49 (0) 201 77 66 88ku?ttner E entstaub 07-09-04:6-Seiter 10.09.2007 12:20 Uhr Seite 16315eDuring hot metal productionas well as in steel works andin foundries emissions arise atvery different locations. Theseemissions must be reliablycaptured and filtered.Besides intensive filtering, efficiency plays a keyrole. The emissions must be extracted with as littlefalse air as possible. Moreover, the pressure loss inthe duct system must be minimized.Both the exhaust and the air transport in the ductsystem of KÜTTNER dedusting plants are sys-tematically optimized in terms of flow technology.This markedly reduces the operating costs of filterplants. The KÜTTNER systems only exhaust air thatneeds cleaning – clean ambient air is not “unne-cessarily” filtered. This improves the capturing effi-ciency, while maintaining the volumetric flow con-stant, or it reduces the volumetric flow, while main-taining the same level of cleaning efficiency.The engineering company, which was foun-ded in 1949 by Dr. Carl Küttner, has evolvedinto a group of companies active worldwidein engineering turn-key process, melting andconveying plants for the metals producingand processing industry.The “dedusting technology” division hasevolved from the engineering of ancillaryplants for “processing technology” applicati-ons. Through its intensive engagement withflow simulation issues, KÜTTNER has becomea highly competent partner also in the con-struction of large-scale dedusting facilities.The service range comprises the planning,design, delivery, assembly as well as commis-sioning of plants complete with control anddata processing systems.The KÜTTNER Group today has a worldwideworkforce of 400. It is represented in theinternational markets through a network ofagents and affiliated companies. The majori-ty of its owners actively work in the company.OPTIMIZED EXTRACTION OF EMISSIONSACHIEVES COST ADVANTAGESKÜTTNER GMBH & CO. KGWhen dealingwith largeexhaust air volu-mes, only a detai-led flow-technolo-gical investigationcan guarantee anoptimal design ofall componentsvoestalpineStahl GmbH,LinzBlast furnace 4-6Cast house withextraction equip-ment, filter plantand blowerhouse5,5 mDEDUSTING SYSTEMSfor Blast Furnaces and Steel WorksEfficient Exhaust GasExtractionReduction of Filter CostsEnergy SavingsEco-Friendly Operationinfo@kuettner.dewww.kuettner.deKüttner GmbH & Co. KGBismarckstr. 67 · 45128 EssenPhone +49 (0) 201 72 93-0Fax +49 (0) 201 77 66 88ku?ttner E entstaub 07-09-04:6-Seiter 10.09.2007 12:20 Uhr Seite 1When the hot metal is poured into the converter, agreat number of different emissions are released.The scrap charge might contain combustible consti-tuents such as residues of plastics, oil, grease, lac-quers or alike. Upon addition of the hot metal thesesubstances immediately decompose (pyrolysis),mainly turning into gaseous hydrocarbons (CH4and other compounds), carbon monoxide andhydrogen.Also metallic dusts, for example zinc, may vapori-ze and enter into the gaseous phase. Wateradhering to the scrap may dissociate and releasehydrogen.These constituents combust inside and partly outsi-de the converter. The arising flue gases are captu-red to the greatest possible extent by exhausthoods of the cyclone type and conveyed to the fil-ter plant through the duct system.The flue gases have an average temperatureof about 800 °C, with peak temperatures of about1,000 °C. By simultaneously extracting the fluegases by several hoods the gases are mixed andcooled down at the duct walls to some 450 °C.A mass heat accumulator cools the extractedfume gases down to the filter inlet temperature.The accumulated heat is stored in steel plates andreleased back to the ambient air within 20 minu-tes from the completion of the converter chargingoperation. The ambient air in the converter houseserves as cooling medium.The coarse dust fractions are separated from theextracted fume gases already in the pre-separator.The fine particles are retained in the bag filters.From the filter bags the cleaned exhaust air is con-veyed to the clean gas duct, from there via exhau-stors to a silencer and a stack, which releases itinto the open air.FLOW OPTIMIZATION:COST REDUCTIONCAST HOUSE:ONLY CONTAMINATED AIR IS CLEANEDCONVERTER:COOLING WITHOUT MEDIANozzle plates:Nozzle platesefficiently extractexhaust gasesalso from farbelow.Cyclone hoods:Cyclone hoodsprovide goodprotection againsttransverse flows.Even impulsiveemissions are reli-ably captured.During the various phases of blast furnace operation, forexample tapping, tap-hole drilling and plugging, emissionsarise at the tap hole, the air duct and the tilting runner. Theseemissions must be reliably captured and filtered. They mainlyconsist of particulate products from the chemical reaction bet-ween the melt and the oxygen in the ambient air and crystal-line carbon sublimated from the melt.The large surface of the iron runner at the tap hole releasesfairly intensive heat to the environment, forming a stable con-vective flow above the pouring stream. At this locationKÜTTNER employs cyclone hoods which have proved to beparticularly suitable for impulsive convective flows. They arearranged outside the swivelling range of the drilling andplugging machines. At the skimmer and the tilting launderclosed hoods are used.The flow-technological optimization of all components ensu-res that released emissions are securely captured and extrac-tion of false air is minimized. Also the effect of transverseflows is minimal. The exhaust ducts at the individual emissionpoints are equipped with air control dampers. They are inte-grated into the process flow enabling the setting of optimalsuction conditions in any operating situation.Also the exhausting ducts, which convey the dust-laden air tothe filters, are investigated and designed according to flow-technological aspects. This makes for low pressure losses inthe duct system and minimizes energy requirements.The filter system is made up of a pre-separator, which remo-ves coarse dust fractions, and a filter with filter bags thatremoves the fines. Exhaustors convey the cleaned exhaust airthrough the clean gas duct, a silencer and a stack, whichreleases it into the open air. Due to the low pressure losses inthe overall system the fans can be downsized compared toconventional systems.In the stack the volumetric flow and the dust content of theclean gas are continuously measured. In this way it is possi-ble to check at any time whether the emission values arewithin regulatory limits.In Hot Metal Production• Coke making plants• Sinter plants• Blast furnaces– Burden preparation– Coal drying/combined drying and grinding– Cast house• Shaft furnacesIn Steel Works• Hot metal desulfurization• Alloying plants• Converters• Ladle handlingIn Foundries• Induction furnace plants• Pouring plants• Sand preparation• Moulding plants• Shake-out and conveying equipmentSuction ducts:Capturingsystems indivi-dually designedfor the specifictask use nozzleplates and cyclo-ne hoods as basicelements.EKO Stahl,EisenhüttenstadtBasic oxygensteel worksSimulation ofexhaust gascapturingThyssenKruppSteel, DuisburgHO1Air extraction atthe tilting runner ata rate of 290,000Bm3/hThyssenKruppSteel, DuisburgHO1Air extraction atthe tap hole at arate of 125,000Bm3/h and at themain runner andthe air duct at arate of 500,000Bm3/hReduced energy require-ments through optimizedflow rate distributionHigher efficiency throughlow pressure lossesHeataccumulatorThe mass heataccumulator is asimple and sturdycomponent, whichmakes complexcooling systemsunnecessaryIndividually Tailored to SpecificConditions on SiteKÜTTNER uses components optimally suited for each spe-cific task. One example is the nozzle plate for efficientexhaust air capturing, being highly superior to conventionalhoods.KÜTTNER also employs suction hoods working on thecyclone principle. Cyclone hoods are particularly suitedfor capturing turbulent, impulsive emission currents, such asthermal convection flows at the blast furnace tap holeabove the iron runner.The line-shaped cyclone thread forming inside thehoods causes uniform pressure distribution, enabling thehood to capture the exhaust air very smoothly also overlonger distances.ku?ttner E entstaub 07-09-04:6-Seiter 10.09.2007 12:20 Uhr Seite 2When the hot metal is poured into the converter, agreat number of different emissions are released.The scrap charge might contain combustible consti-tuents such as residues of plastics, oil, grease, lac-quers or alike. Upon addition of the hot metal thesesubstances immediately decompose (pyrolysis),mainly turning into gaseous hydrocarbons (CH4and other compounds), carbon monoxide andhydrogen.Also metallic dusts, for example zinc, may vapori-ze and enter into the gaseous phase. Wateradhering to the scrap may dissociate and releasehydrogen.These constituents combust inside and partly outsi-de the converter. The arising flue gases are captu-red to the greatest possible extent by exhausthoods of the cyclone type and conveyed to the fil-ter plant through the duct system.The flue gases have an average temperatureof about 800 °C, with peak temperatures of about1,000 °C. By simultaneously extracting the fluegases by several hoods the gases are mixed andcooled down at the duct walls to some 450 °C.A mass heat accumulator cools the extractedfume gases down to the filter inlet temperature.The accumulated heat is stored in steel plates andreleased back to the ambient air within 20 minu-tes from the completion of the converter chargingoperation. The ambient air in the converter houseserves as cooling medium.The coarse dust fractions are separated from theextracted fume gases already in the pre-separator.The fine particles are retained in the bag filters.From the filter bags the cleaned exhaust air is con-veyed to the clean gas duct, from there via exhau-stors to a silencer and a stack, which releases itinto the open air.FLOW OPTIMIZATION:COST REDUCTIONCAST HOUSE:ONLY CONTAMINATED AIR IS CLEANEDCONVERTER:COOLING WITHOUT MEDIANozzle plates:Nozzle platesefficiently extractexhaust gasesalso from farbelow.Cyclone hoods:Cyclone hoodsprovide goodprotection againsttransverse flows.Even impulsiveemissions are reli-ably captured.During the various phases of blast furnace operation, forexample tapping, tap-hole drilling and plugging, emissionsarise at the tap hole, the air duct and the tilting runner. Theseemissions must be reliably captured and filtered. They mainlyconsist of particulate products from the chemical reaction bet-ween the melt and the oxygen in the ambient air and crystal-line carbon sublimated from the melt.The large surface of the iron runner at the tap hole releasesfairly intensive heat to the environment, forming a stable con-vective flow above the pouring stream. At this locationKÜTTNER employs cyclone hoods which have proved to beparticularly suitable for impulsive convective flows. They arearranged outside the swivelling range of the drilling andplugging machines. At the skimmer and the tilting launderclosed hoods are used.The flow-technological optimization of all components ensu-res that released emissions are securely captured and extrac-tion of false air is minimized. Also the effect of transverseflows is minimal. The exhaust ducts at the individual emissionpoints are equipped with air control dampers. They are inte-grated into the process flow enabling the setting of optimalsuction conditions in any operating situation.Also the exhausting ducts, which convey the dust-laden air tothe filters, are investigated and designed according to flow-technological aspects. This makes for low pressure losses inthe duct system and minimizes energy requirements.The filter system is made up of a pre-separator, which remo-ves coarse dust fractions, and a filter with filter bags thatremoves the fines. Exhaustors convey the cleaned exhaust airthrough the clean gas duct, a silencer and a stack, whichreleases it into the open air. Due to the low pressure losses inthe overall system the fans can be downsized compared toconventional systems.In the stack the volumetric flow and the dust content of theclean gas are continuously measured. In this way it is possi-ble to check at any time whether the emission values arewithin regulatory limits.In Hot Metal Production• Coke making plants• Sinter plants• Blast furnaces– Burden preparation– Coal drying/combined drying and grinding– Cast house• Shaft furnacesIn Steel Works• Hot metal desulfurization• Alloying plants• Converters• Ladle handlingIn Foundries• Induction furnace plants• Pouring plants• Sand preparation• Moulding plants• Shake-out and conveying equipmentSuction ducts:Capturingsystems indivi-dually designedfor the specifictask use nozzleplates and cyclo-ne hoods as basicelements.EKO Stahl,EisenhüttenstadtBasic oxygensteel worksSimulation ofexhaust gascapturingThyssenKruppSteel, DuisburgHO1Air extraction atthe tilting runner ata rate of 290,000Bm3/hThyssenKruppSteel, DuisburgHO1Air extraction atthe tap hole at arate of 125,000Bm3/h and at themain runner andthe air duct at arate of 500,000Bm3/hReduced energy require-ments through optimizedflow rate distributionHigher efficiency throughlow pressure lossesHeataccumulatorThe mass heataccumulator is asimple and sturdycomponent, whichmakes complexcooling systemsunnecessaryIndividually Tailored to SpecificConditions on SiteKÜTTNER uses components optimally suited for each spe-cific task. One example is the nozzle plate for efficientexhaust air capturing, being highly superior to conventionalhoods.KÜTTNER also employs suction hoods working on thecyclone principle. Cyclone hoods are particularly suitedfor capturing turbulent, impulsive emission currents, such asthermal convection flows at the blast furnace tap holeabove the iron runner.The line-shaped cyclone thread forming inside thehoods causes uniform pressure distribution, enabling thehood to capture the exhaust air very smoothly also overlonger distances.ku?ttner E entstaub 07-09-04:6-Seiter 10.09.2007 12:20 Uhr Seite 2When the hot metal is poured into the converter, agreat number of different emissions are released.The scrap charge might contain combustible consti-tuents such as residues of plastics, oil, grease, lac-quers or alike. Upon addition of the hot metal thesesubstances immediately decompose (pyrolysis),mainly turning into gaseous hydrocarbons (CH4and other compounds), carbon monoxide andhydrogen.Also metallic dusts, for example zinc, may vapori-ze and enter into the gaseous phase. Wateradhering to the scrap may dissociate and releasehydrogen.These constituents combust inside and partly outsi-de the converter. The arising flue gases are captu-red to the greatest possible extent by exhausthoods of the cyclone type and conveyed to the fil-ter plant through the duct system.The flue gases have an average temperatureof about 800 °C, with peak temperatures of about1,000 °C. By simultaneously extracting the fluegases by several hoods the gases are mixed andcooled down at the duct walls to some 450 °C.A mass heat accumulator cools the extractedfume gases down to the filter inlet temperature.The accumulated heat is stored in steel plates andreleased back to the ambient air within 20 minu-tes from the completion of the converter chargingoperation. The ambient air in the converter houseserves as cooling medium.The coarse dust fractions are separated from theextracted fume gases already in the pre-separator.The fine particles are retained in the bag filters.From the filter bags the cleaned exhaust air is con-veyed to the clean gas duct, from there via exhau-stors to a silencer and a stack, which releases itinto the open air.FLOW OPTIMIZATION:COST REDUCTIONCAST HOUSE:ONLY CONTAMINATED AIR IS CLEANEDCONVERTER:COOLING WITHOUT MEDIANozzle plates:Nozzle platesefficiently extractexhaust gasesalso from farbelow.Cyclone hoods:Cyclone hoodsprovide goodprotection againsttransverse flows.Even impulsiveemissions are reli-ably captured.During the various phases of blast furnace operation, forexample tapping, tap-hole drilling and plugging, emissionsarise at the tap hole, the air duct and the tilting runner. Theseemissions must be reliably captured and filtered. They mainlyconsist of particulate products from the chemical reaction bet-ween the melt and the oxygen in the ambient air and crystal-line carbon sublimated from the melt.The large surface of the iron runner at the tap hole releasesfairly intensive heat to the environment, forming a stable con-vective flow above the pouring stream. At this locationKÜTTNER employs cyclone hoods which have proved to beparticularly suitable for impulsive convective flows. They arearranged outside the swivelling range of the drilling andplugging machines. At the skimmer and the tilting launderclosed hoods are used.The flow-technological optimization of all components ensu-res that released emissions are securely captured and extrac-tion of false air is minimized. Also the effect of transverseflows is minimal. The exhaust ducts at the individual emissionpoints are equipped with air control dampers. They are inte-grated into the process flow enabling the setting of optimalsuction conditions in any operating situation.Also the exhausting ducts, which convey the dust-laden air tothe filters, are investigated and designed according to flow-technological aspects. This makes for low pressure losses inthe duct system and minimizes energy requirements.The filter system is made up of a pre-separator, which remo-ves coarse dust fractions, and a filter with filter bags thatremoves the fines. Exhaustors convey the cleaned exhaust airthrough the clean gas duct, a silencer and a stack, whichreleases it into the open air. Due to the low pressure losses inthe overall system the fans can be downsized compared toconventional systems.In the stack the volumetric flow and the dust content of theclean gas are continuously measured. In this way it is possi-ble to check at any time whether the emission values arewithin regulatory limits.In Hot Metal Production• Coke making plants• Sinter plants• Blast furnaces– Burden preparation– Coal drying/combined drying and grinding– Cast house• Shaft furnacesIn Steel Works• Hot metal desulfurization• Alloying plants• Converters• Ladle handlingIn Foundries• Induction furnace plants• Pouring plants• Sand preparation• Moulding plants• Shake-out and conveying equipmentSuction ducts:Capturingsystems indivi-dually designedfor the specifictask use nozzleplates and cyclo-ne hoods as basicelements.EKO Stahl,EisenhüttenstadtBasic oxygensteel worksSimulation ofexhaust gascapturingThyssenKruppSteel, DuisburgHO1Air extraction atthe tilting runner ata rate of 290,000Bm3/hThyssenKruppSteel, DuisburgHO1Air extraction atthe tap hole at arate of 125,000Bm3/h and at themain runner andthe air duct at arate of 500,000Bm3/hReduced energy require-ments through optimizedflow rate distributionHigher efficiency throughlow pressure lossesHeataccumulatorThe mass heataccumulator is asimple and sturdycomponent, whichmakes complexcooling systemsunnecessaryIndividually Tailored to SpecificConditions on SiteKÜTTNER uses components optimally suited for each spe-cific task. One example is the nozzle plate for efficientexhaust air capturing, being highly superior to conventionalhoods.KÜTTNER also employs suction hoods working on thecyclone principle. Cyclone hoods are particularly suitedfor capturing turbulent, impulsive emission currents, such asthermal convection flows at the blast furnace tap holeabove the iron runner.The line-shaped cyclone thread forming inside thehoods causes uniform pressure distribution, enabling thehood to capture the exhaust air very smoothly also overlonger distances.ku?ttner E entstaub 07-09-04:6-Seiter 10.09.2007 12:20 Uhr Seite 26315eDuring hot metal productionas well as in steel works andin foundries emissions arise atvery different locations. Theseemissions must be reliablycaptured and filtered.Besides intensive filtering, efficiency plays a keyrole. The emissions must be extracted with as littlefalse air as possible. Moreover, the pressure loss inthe duct system must be minimized.Both the exhaust and the air transport in the ductsystem of KÜTTNER dedusting plants are sys-tematically optimized in terms of flow technology.This markedly reduces the operating costs of filterplants. The KÜTTNER systems only exhaust air thatneeds cleaning – clean ambient air is not “unne-cessarily” filtered. This improves the capturing effi-ciency, while maintaining the volumetric flow con-stant, or it reduces the volumetric flow, while main-taining the same level of cleaning efficiency.The engineering company, which was foun-ded in 1949 by Dr. Carl Küttner, has evolvedinto a group of companies active worldwidein engineering turn-key process, melting andconveying plants for the metals producingand processing industry.The “dedusting technology” division hasevolved from the engineering of ancillaryplants for “processing technology” applicati-ons. Through its intensive engagement withflow simulation issues, KÜTTNER has becomea highly competent partner also in the con-struction of large-scale dedusting facilities.The service range comprises the planning,design, delivery, assembly as well as commis-sioning of plants complete with control anddata processing systems.The KÜTTNER Group today has a worldwideworkforce of 400. It is represented in theinternational markets through a network ofagents and affiliated companies. The majori-ty of its owners actively work in the company.OPTIMIZED EXTRACTION OF EMISSIONSACHIEVES COST ADVANTAGESKÜTTNER GMBH & CO. KGWhen dealingwith largeexhaust air volu-mes, only a detai-led flow-technolo-gical investigationcan guarantee anoptimal design ofall componentsvoestalpineStahl GmbH,LinzBlast furnace 4-6Cast house withextraction equip-ment, filter plantand blowerhouse5,5 mDEDUSTING SYSTEMSfor Blast Furnaces and Steel WorksEfficient Exhaust GasExtractionReduction of Filter CostsEnergy SavingsEco-Friendly Operationinfo@kuettner.dewww.kuettner.deKüttner GmbH & Co. KGBismarckstr. 67 · 45128 EssenPhone +49 (0) 201 72 93-0Fax +49 (0) 201 77 66 88ku?ttner E entstaub 07-09-04:6-Seiter 10.09.2007 12:20 Uhr Seite 1