DC Document No.

2X00680F2-B100-D001
Rev. 0
Document No.

COMPAÑIA SIDERÚRGICA HUACHIPATO S.A.

HOT METAL DESULPHURIZATION PLANT AND DEDUSTING SYSTEM

BASIC ENGINEERING TECHNICAL

SPECIFICATION

All rights reserved; confidential. This document is prepared by Danieli Corus Inc. entailing valuable know-how owned by Danieli
Corus Inc. and is supplied only for the specific use as authorized by written agreement. This document shall not be disclosed, used
or reproduced either wholly or in part except in connection with such authorized use and then only with the prior written consent of
Danieli Corus Inc. This document must not be used until signed as checked and approved by Danieli Corus Inc.
© 2005 Danieli Corus Inc.

0 15 APR 2005 Issue For Construction M.L-A H.C. X.H.

Rev. Date Description Prepared Checked Approved Owner
Document3 CSH Project No.: 456233-H1-01 Page 1 of 27
DC Project No.: 2X00680.C
REVISION SHEET

Rev Date Section Page Description

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Document No.: 2X00680F2-B100-D001 Rev.: 0
Table of Contents

1. GENERAL..................................................................................................................... 5
1.1 Introduction ................................................................................................................. 5
1.2 Facility Configuration................................................................................................... 5
1.3 Process Design Criteria .............................................................................................. 6
1.4 Design Criteria - Health and Safety............................................................................. 6

2. STRUCTURAL STEEL ................................................................................................. 7

2.1 Reference Drawings.................................................................................................... 7
2.2 Requirements.............................................................................................................. 8
2.3 Work Distribution......................................................................................................... 8

3. PROCESS EQUIPMENT .............................................................................................. 8

3.1 Injection Lance Hoist................................................................................................... 8
3.2 Temperature/Sampling Hoist .................................................................................... 10
3.3 Magnesium Storage Silo ........................................................................................... 11
3.4 Lime Storage Silo...................................................................................................... 12
3.5 Dispensers ............................................................................................................... 13
3.6 Transporters.............................................................................................................. 14
3.7 Lance Loading Arm ................................................................................................... 15

4. PIPING SYSTEMS...................................................................................................... 17
4.1 Description ................................................................................................................ 17
4.2 Design Criteria .......................................................................................................... 17
4.3 Materials ................................................................................................................... 18
4.4 Cleaning and Testing Requirements......................................................................... 19

5. PULPIT AND EQUIPMENT ROOMS.......................................................................... 20

5.1 Scope of Work .......................................................................................................... 20
5.2 Climate Control ......................................................................................................... 20
5.3 Reference Drawings.................................................................................................. 21
5.4 Work Distribution....................................................................................................... 21

6. PROCESS CONTROL (INSTRUMENTATION/AUTOMATION) ................................. 21

6.1 Instrumentation ......................................................................................................... 21
6.2 Automation System ................................................................................................... 25
6.3 Scope of Work .......................................................................................................... 25
6.4 Testing and Pre-Commissioning Requirement ......................................................... 27

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 6.5 Standards and Specifications.................................................................................... 27

7. ELECTRICAL SYSTEMS............................................................................................ 27
7.1 General Information .................................................................................................. 27
7.2 Working Scope.......................................................................................................... 27
7.3 Grounding Requirement............................................................................................ 27
7.4 Cable Installation ...................................................................................................... 27
7.5 Power Distribution ..................................................................................................... 27
7.6 Field Mounted Equipment ......................................................................................... 27
7.7 Take Over Point ........................................................................................................ 27
7.8 Reference Document ................................................................................................ 27
7.9 Design Criteria .......................................................................................................... 27

8. EMISSION CONTROL SYSTEM ................................................................................ 27

8.1 System Description ................................................................................................... 27
8.2 Reference Drawings.................................................................................................. 27
8.3 Definition of Emissions.............................................................................................. 27
8.4 System Design Parameters ...................................................................................... 27
8.5 Disposal .................................................................................................................... 27
8.6 System Performance Data ........................................................................................ 27

9. MATERIAL SAFETY DATA SHEETS ......................................................................... 27

9.1 Lime .......................................................................................................................... 27
9.2 Magnsium ................................................................................................................. 27

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1. GENERAL

1.1 Introduction

This technical specification summarizes the Basic Engineering of the Hot Metal Desulphurization
Plant and De-dusting System completed by Danieli Corus Inc. (DC) for Compañia Siderúrgica
Huachipato S.A. (CSH).
The specification, supplemented by a set of basic engineering drawings, provides all the process
related information and technical “know-how” for CSH’s engineering organization to obtain the
necessary project approvals, complete detail engineering, procurement and construction of the
above facility.
This document and the attached engineering drawings contain technical information that is
proprietary to Danieli Corus. In this regard, use of this document, including all of its
attachments, is limited to the above specified project and activities.

1.2 Facility Configuration

1.2.1 Reference Drawings

2X00680.F2-M100-C001 Facility Layout, Key Plan
2X00680.F2-M100-C002 Facility Layout, Section A-A
2X00680.F2-M100-C003 Facility Layout, Elevation
2X00680.F2-M100-C004 Facility Layout, Plan at Pits El. 0.00
2X00680.F2-M100-C005 Facility Layout, Detail Plans
2X00680.F2-M100-C006 Facility Layout, Lance Rack Assembly
2X00680.F2-M100-C007 Facility Layout, Silos Detail Plans and Sections
2X00680.F2-M100-C010 Facility Layout, Temperature/Sampling Hoist, General
Arrangement
2X00680.F2-M100-C012 Injection Lance Hoist, General Arrangement
2X00680.F2-M100-C013 Lance Arm, General Arrangement
2X00680.F2-M100-C014 Reagent Injection System, General Arrangement – Plan Views
2X00680.F2-M100-C015 Proposed Hood Lifting Device
2X00680.F2-M100-C020 De-dusting Piping, Plan View
2X00680.F2-M100-C021 De-dusting Piping, Section A-A
2X00680.F2-M100-C022 De-dusting Piping, Section B-B
2X00680.F2-M100-C024 Injection Hood, General Arrangement

1.2.2 Description

The two (2) hot metal desulphurization stations are located inside the steel shop adjacent to the
hot metal transfer pits between column lines 2 and 4 as shown on the above reference drawings.
The de-dusting system is located next to the existing primary dust collector outside of the steel
shop.
The desulphurization and dedusting systems comprise the following equipment:

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 Two (2) injection lance hoists
Two (2) temperature/sampling hoists
Two (2) lance loading arms
One (1) 1.5T lance unloading jib crane
One (1) 3T magnesium unloading hoist
Two (2) silos
Two (2) transporters
Two (2) dispensers
Two (2) fume emission control hoods (injection hoods)
One (1) baghouse
Two (2) exhaust fans and motors
One (1) nitrogen supply system
One (1) lime unloading station
One (1) Process Control level 1 system including PLC cabinets, panels and HMI
One (1) LECO sulphur analyzer
Two (2) temperature measurement instruments
One (1) oxygen analyzer
One (1) moisture analyzer
One (1) Process Control level 2 system

1.3 Process Design Criteria

The facility is designed in compliance with the requirements as identified in the contract document
456233-HI-01 between Danieli Corus and CSH.
In addition, the station and associated equipment is designed to accommodate the
drawings received during the kick-off meeting.

1.4 Design Criteria - Health and Safety

1.4.1 General

In USA and Canada, there is no specific standard or government regulation in the health and
safety area which would be directly applicable to the design of metallurgical facilities using
magnesium and lime.
However, the following general criteria, which are accepted by government agencies and
insurance underwriters, are being applied in the design of these facilities.

1.4.2 Fire Protection

Magnesium may ignite in air if the metal temperature is raised close to melting point. The
probability of ignition depends on the mass and dimension of the material and the intensity of the
ignition source. The ignition temperature varies from 540ºC for fine dust to 650ºC for coarse
materials.
Chemical reaction between water and magnesium produces hydrogen gas and, because the
reaction is exothermic, wet magnesium is capable of igniting by itself.

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In the desulphurization facility, magnesium and lime are handled in closed vessels and piping in a
dry nitrogen atmosphere; hence, only relatively small spills may occur during maintenance
procedures.
Fire Prevention Measures in the reagent handling area where blend spills may occur are:
no smoking or use of open fire
prevention of water leaks
good housekeeping - clean up spills: spilled reagent is usually swept, using a
plastic dust pan and broom, into plastic bags which can be thrown into the hot metal
proper grounding of reagent handling system
Fire Protection Equipment:
Since a number of fire extinguishers use water based foam or chemical, which can
promote magnesium fires, dry sand is commonly used to extinguish small reagent fires.
Therefore, bins of dry sand should be strategically located in the facility.
No other fire protecting measures, such as automatic fire extinguishing systems, fire
walls, etc. are being applied at these facilities.

1.4.3 Explosion Protection

Explosivity index of the magnesium/lime blend according to the U.S. Bureau of Mines is 0.000. On
that basis, no special provisions against an explosion are required.

1.4.4 Health Hazards

Ingestion, eye contact, skin contact, and inhalation should be prevented by protective wear and
safety glasses; measures which are commonly applied in the iron and steel industry.

1.4.5 Gas Hazards

Nitrogen gas is used in relatively large quantities for storage and transportation of magnesium/lime
reagent. Hence, gas discharge in closed areas should be prevented by means of directing gas
discharges from the bin vents and safety valves to outside the building.

2. STRUCTURAL STEEL

2.1 Reference Drawings

Drawing No. Description

2X00680.F2-M100-C001 Facility Layout, Key Plan
2X00680.F2-M100-C002 Facility Layout, Section A-A
2X00680.F2-M100-C003 Facility Layout, Elevation
2X00680.F2-M100-C004 Facility Layout, Plan at Pits El. 0.00
2X00680.F2-M100-C005 Facility Layout, Detail Plans
2X00680.F2-M100-C006 Facility Layout, Lance Rack Assembly

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 2X00680.F2-M100-C007 Facility Layout, Silos Detail Plans and Sections
2X00680.F2-M100-C010 Facility Layout, Temperature/Sampling Hoist, General
Arrangement
2X00680.F2-M100-C012 Facility Layout, Injection Lance Hoist, General Arrangement
2X00680.F2-M100-C013 Facility Layout, Lance Loading Arm, General Arrangement
2X00680.F2-M100-C014 Facility Layout, Reagent Dispensers, General Arrangement
2X00680.F2-M100-C015 Facility Layout, Proposed Hood Lifting Device
2X00680.F2-M100-C020 Facility Layout, De-Dusting Piping, Plan View
2X00680.F2-M100-C021 Facility Layout, De-Dusting Piping, Section A-A
2X00680.F2-M100-C022 Facility Layout, De-Dusting Piping, Section B-B
2X00680.F2-M100-C024 Facility Layout, Injection Hood, General Arrangement

2.2 Requirements

The basic engineering drawings convey the following requirements which must be satisfied during
the “detail engineering” phase:
platform locations, elevation, and footprints
platform design live loads to suit operational requirements
platform equipment drawing references for base plate details, location, loading and range
of movements
platform hole requirements
locations of stairs and walkways

2.3 Work Distribution

Basic engineering (facility layouts only) by Danieli Corus.

Detail engineering by CSH.
Supply and installation of all materials by CSH.

3. PROCESS EQUIPMENT

3.1 Injection Lance Hoist

The facility includes two (2) injection lance hoists.

3.1.1 Description

Each injection lance hoist is designed to lower the reagent lance into the hot metal ladle. The
movement is completed in three (3) positions, as follows:
park position
start reagent flow (lance tip positioned about 200 mm above surface of hot metal)
blowing position (about 300 mm above ladle bottom)
The lowering and raising of the lance is accomplished via the actuating 18.75 kW electric motor
with variable frequency drive control. A multi turn encoder and one (1) interlocking limit switch

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control the position of the injection lance hoist. Two (2) over travel limit switches provide
emergency backup to stop the carriage.
The injection lance hoist is constructed from structural shapes and plates, and is complete with
lance holder assembly.
The injection hoist is comprised of the following components:
mast
trolley frame assembly
lift drive assembly
electric motor, complete with gearbox and brake
reagent supply piping
roller chains
encoder
Basic Design Data
Approximate weight of one (1) hoist ........................................................... 3100 kg
Approximate weight of one (1) lance ............................................................ 650 kg
Approximate lance tip speed ....................................................................... 0.7 m/s
Injection lance travel................................................................................. 7230 mm
Number of operations per heat.............................................................................. 1
Number of heats per day ..................................................................................... 35

3.1.2 Reference Drawings

2X00680.F2-M100-C001 Facility Layout, Key Plan

2X00680.F2-M100-C002 Facility Layout, Section A-A
2X00680.F2-M100-C003 Facility Layout, Elevation
2X00680.F2-M100-C004 Facility Layout, Plan at Pits El. 0.00
2X00680.F2-M100-C005 Facility Layout, Detail Plans
2X00680.F2-M100-C012 Facility Layout, Injection Lance Hoist, General Arrangement
2X00680.F2-M100-C013 Facility Layout, Lance Loading Arm, General Arrangement
2X00680.F2-M610-C001 Injection Lance Hoist General Assembly
2X00680.F2-M610-C002 Carriage and Extension Arm, Sub-Assembly
2X00680.F2-M610-C003 Reagent Supply Piping and Support, Sub-Assembly
2X00680.F2-M610-C004 Encoder Sub-Assembly
2X00680.F2-Q203-C325 Terminal Box Layout and Wiring Diagram – Station 1
2X00680.F2-Q203-C326 Terminal Box Layout and Wiring Diagram – Station 2

3.1.3 Components
Per material list Dwg. No. 2X00680.F2-M610-C001, 2X00680.F2-M610-C002,
2X00680.F2-M610-C003, 2X00680.F2-M610-C004.
Bill of material includes such key components, as:
electric motor, complete with gearbox and brake
roller chain, complete with sprockets
limit switches and encoder
terminal box

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3.1.4 Work Distribution

Basic engineering by Danieli Corus.

Detail engineering by Danieli Corus.
Supply and manufacturing by Danieli Corus.
On-site installation by CSH.

3.2 Temperature/Sampling Hoist

The facility includes two (2) temperature/sampling hoists.

3.2.1 Description

Each temperature and sampling hoist is designed to lower and raise the temperature and sampling
probe into and from the hot metal bath.
The lowering and razing of the probes is accomplished via one (1) 1.5 kW electric motor, complete
with gearbox and brake. There is one probe carriage for simultaneous temperature measurement
and sampling. One (1) multi turn encoder and one (1) interlocking limit switch define the position of
the probe. Two (2) over travel limit switches provide emergency backup to stop the carriage.
The hoist is constructed from structural shapes and plates, and is complete with lance holder.
The probe lance travel geometry is within a range as defined on the reference drawing, namely:
Approximate weight of one (1) hoist ..................................................... 1050 kg
lance travel ........................................................................................ 6320 mm
temperature/sampling probe length ................................................... 1480 mm
Basic Design Data
Approximate lance tip speed ..................................................................... 0.6 m/s
Approximate sampling time ........................................................................... 6 sec
Number of operations per heat ............................................................................ 2
Number of heats per day ................................................................................... 35

3.2.2 Reference Drawings

Drawing No. Description

2X00680.F2-M100-C001 Facility Layout, Key Plan
2X00680.F2-M100-C003 Facility Layout, Elevation
2X00680.F2-M100-C004 Facility Layout, Plan at Pits El. 0.00
2X00680.F2-M100-C005 Facility Layout, Detail Plans
2X00680.F2-M100-C010 Facility Layout, Temperature/Sampling Hoist, General
Arrangement
2X00680.F2-M615-C001 Temperature and Sampling Hoist, General Assembly
2X00680.F2-M615-C002 Temperature and Sampling Hoist, Upper/Lower Base
Sub-Assembly
2X00680.F2-M615-C003 Carriage, Sub-Assembly
2X00680.F2-M615-C004 Temperature Probe, Sub-Assembly

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3.2.3 Components

Per bill of material Dwg. No. 2X00680.C /M615-C001, 2X00680.C /M615-C002,

2X00680.C/M615-C003, 2X00680.C/M615-C004.
Bill of material includes such key components, as:
electric motor complete with gearbox and brake
roller chain complete with sprockets
encoder
limit switches and encoder
terminal box

3.2.4 Work Distribution

Basic engineering by Danieli Corus.

Detail engineering by Danieli Corus.
Supply and manufacturing by Danieli Corus.
On-site installation by CSH.

3.3 Magnesium Storage Silo

The facility includes one (1) magnesium storage silo.

3.3.1 Description

The 50 m3 magnesium storage silo is designed to be filled using super sacks, about 1,000 kg
magnesium particulates per bag. The silo is equipped with two (2) level switches to assist loading,
discharging, and reordering activities.
The magnesium super sack unloader will sit on top of the silo. The dedicated service hoist
will lift the super sacks onto the unloading hopper, and the magnesium powder will drain into the
silo by gravity.
Nitrogen will be used to blanket the silo in a dry environment at all times.
A cartridge type dust collector is equipped on top of the silo to handle the venting from the
magnesium dispenser depressurization and silo cone fluidization process.
The super sack unloading station, dust collector, and the entire silo are enclosed within the steel
shop and thus will be protected against entry of rain, snow, or water.
The oxygen level will be monitored to prevent moisture or water presence inside the silo.
When the process demands a batch of magnesium, nitrogen is injected into the silo cone to insure
fluidization of the magnesium. The fluid magnesium will then pour by gravity into the transporter
located below the silo cone and then pneumatically convey to the dispenser sit on the elevated
platform in the injection station.

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3.3.2 Reference Drawings

2X00680.F2-M100-C001 Facility Layout, Key Plan

2X00680.F2-M100-C003 Facility Layout, Elevation
2X00680.F2-M100-C005 Facility Layout, Detail Plans
2X00680.F2-M100-C007 Facility Layout, Silos Detail Plans and Sections
2X00680.F2-M140-C002 Magnesium Storage Silo, General Arrangement
2X00680.F2-M145-C001 Magnesium Unloading Hopper, General Arrangement
2X00680.F2-M145-C002 Magnesium Unloading Hopper, Details
2X00680.F2-R215-E003A Magnesium Storage Silo, Piping and Instrumentation
Diagram

3.3.3 Components

For identification of components on the magnesium storage silo, refer to the drawings listed in sub-
section 3.5.2.

3.3.4 Work Distribution

Basic engineering by Danieli Corus.

Detail engineering by CSH.
Supply and manufacture by CSH.
On-site installation by CSH.

3.4 Lime Storage Silo

The facility includes one (1) lime storage silo.

3.4.1 Description

The 100 m3 lime storage silo is designed to receive shipments from pneumatic transport trucks.
The silo is equipped with two (2) level switches to assist loading/unloading and reordering
activities.
Nitrogen will be used to convey the lime into the silo and to blanket the silo in a dry environment.
The nitrogen will vent itself out through a dust collector mounted to the silo roof.
The dust collector is a cartridge filter, pulse type unit and is designed to handle the venting from
the lime dispenser depressurization, lime truck unloading and the silo cone fluidization process.
When the process demands a batch of lime, nitrogen is injected into the silo cone to insure
fluidization of the lime. The fluid lime will then pour by gravity into the transporter located below
the silo cone and pneumatically convey to the dispenser sit on the elevated platform in the
injection station.

3.4.2 Reference Drawings

2X00680.F2-M100-C001 Facility Layout, Key Plan

2X00680.F2-M100-C003 Facility Layout, Elevation

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 2X00680.F2-M100-C005 Facility Layout, Detail Plans
2X00680.F2-M100-C007 Facility Layout, Silos Detail Plans and Sections
2X00680.F2-M140-C001 Lime Storage Silo, General Arrangement
2X00680.F2-R215-E001A Lime Storage Silo, Piping and Instrumentation
Diagram

3.4.3 Components

For identification of the components for the lime storage silo, refer to the drawings listed in sub-
section 3.4.2.

3.4.4 Work Distribution

Basic engineering by Danieli Corus.

Detail engineering by Danieli Corus.
Supply and manufacture by CSH.
On-site installation by CSH.

3.5 Dispensers

The facility includes one (1) lime dispenser and one (1) magnesium dispensers.

3.5.1 Description

The dispenser vessels are designed to fluidize and transport reagent to the injection lance using
the co injection process. The lime and magnesium are simultaneously injected into the hot metal.
The co injection station comprises lime and magnesium dispensers with a capacity of 2.27 m3
each, fluidizing and transport manifolds, weighing systems, and controls.

3.5.2 Reference Drawings

2X00680.F2-M100-C001 Facility Layout, Key Plan

2X00680.F2-M100-C002 Facility Layout, Section A-A
2X00680.F2-M100-C003 Facility Layout, Elevation
2X00680.F2-M100-C005 Facility Layout, Detail Plans
2X00680.F2-M100-C014 Facility Layout, Reagent Injection System
2X00680.F2-M605-C001 Injection System, General Arrangement, Plan Views
2X00680.F2-M605-C002 Injection System, Section A-A, B-B
2X00680.F2-M605-C003 Lime Dispenser, Control Manifold Elevation
2X00680.F2-M605-C004 Magnesium Dispenser, Control Manifold Elevation
2X00680.F2-M605-C005 Dispenser Control Manifold, Sections and Details
2X00680.F2-M605-C006 Dispenser Top, Instrumentation
2X00680.F2-M605-C007 Injection System, Dispenser Fill Assembly
2X00680.F2-M605-C008 Injection System, Parts List 1 of 2
2X00680.F2-M605-C009 Injection System, Parts List 2 of 2
2X00680.F2-M605-C010 Injection System, Diverter Stan Assembly
2X00680.F2-J100-C001 Process Flow Diagram
2X00680.F2-R215-E002 Lime Dispenser, Piping & Instrumentation Diagram

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 2X00680.F2-R215-E004 Magnesium Dispenser, Piping & Instrumentation Diagram
2X00680.F2-Q203-C331 Panel Layouts, Lime Dispenser PLC Cabinet, Layout
2X00680.F2-Q203-C332 Panel Layouts, Lime Dispenser PLC Cabinet, Back Plate
Alterations
2X00680.F2-Q203-C333 Panel Layouts, Lime Dispenser PLC Cabinet, Bill of Material
2X00680.F2-Q203-C334 Panel Layouts, Lime Dispenser PLC Cabinet, Wiring Diagram
2X00680.F2-Q203-C335 Panel Layouts, Lime Dispenser PLC Cabinet, Equipment
Wiring Diagram
2X00680.F2-Q203-C336 Panel Layouts, Lime Dispenser PLC Cabinet, Junction Box
Detailed Layout

2X00680.F2-Q203-C341 Panel Layouts, Mag Dispenser PLC Cabinet, Layout

2X00680.F2-Q203-C342 Panel Layouts, Mag Dispenser PLC Cabinet, Back Plate
Alterations
2X00680.F2-Q203-C343 Panel Layouts, Mag Dispenser PLC Cabinet, Bill of Material
2X00680.F2-Q203-C344 Panel Layouts, Mag Dispenser PLC Cabinet, Wiring Diagram
2X00680.F2-Q203-C345 Panel Layouts, Mag Dispenser PLC Cabinet, Equipment Wiring
Diagram
2X00680.F2-Q203-C346 Panel Layouts, Mag Dispenser PLC Cabinet, Junction Box
Detailed Layout

3.5.3 Components

For identification of components on the dispensers, refer to the drawings listed in sub-section
3.5.2.

3.5.4 Work Distribution

Basic engineering by Danieli Corus.

Detail engineering by Danieli Corus.
Supply of all components and manufacturing by Danieli Corus.
On-site installation by CSH.

3.6 Transporters

The facility includes one (1) transporter for lime transfer and one (1) transporter for magnesium
transfer.

3.6.1 Description

The transporters are designed to fluidize and transport lime and magnesium reagents from silos to
the respective dispensers. Each transporter comprises conveying pressure vessel designed in
accordance with ASME, section VIII, division 1 of the pressure vessel code, with capacity of 1.7
m3; a nitrogen management panel and a set of instrument and valves which makes the
transporters functional in automatic filling and conveying operations.

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3.6.2 Reference Drawings

2X00680.C/M100-C001 Facility Layout, Key Plan

2X00680.C/M100-C003 Facility Layout, Elevation
2X00680.C/M100-C007 Facility Layout, Silos Detail Plans and Sections
2X00680.C/R215-E001A Lime Storage Silo, Piping & Instrumentation Diagram
2X00680.C/R215-E001B Lime Transporter, Piping & Instrumentation Diagram
2X00680.C/R215-E003A Magnesium Storage Silo, Piping & Instrumentation Diagram
2X00680.C/R215-E003B Magnesium Transporter, Piping & Instrumentation Diagram
D50201 60CF48SV10 Convey Vessel, Magnesium System
D50204 60CF48SV10 Convey Vessel with 4”SCH40 Convey Line,
Magnesium System
D50205 60CF48SV10 Convey Vessel, Lime System
D50206 60CF48SV10 Convey Vessel with 4”SCH40 Convey Line,
Lime System
2X00680.F2-Q203-R154 to 165 Silo PLC cabinet I/O Schematics

3.6.3 Components

For identification of components on the transporters, refer to the drawings listed in sub-section
3.6.2.

3.6.4 Work Distribution

Basic engineering by Danieli Corus.

Detail engineering by Danieli Corus.
Supply of all components and manufacturing by Danieli Corus.
On-site installation by CSH.

3.7 Lance Loading Arm

The facility includes two (2) lance loading arms.

3.7.1 Description

Each lance loading arm is designed to transfer the reagent lance from the lance rack location to
injection lance hoist. The movement of the arm is completed in two (2) positions, as follows:
Lance loading position from lance rack to the lance loading arm
Lance loading position from the lance loading arm to the hoist
The moving of the lance is accomplished via the actuating 0.25 kW electric motor. Two (2) limit
switches control the position of the lance arm.
The lance loading arm is constructed from structural shapes and plates, and is complete with lance
holder bracket.
The lance loading arm is comprised of the following components:
arm weldment

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 top drive assembly
bottom bearing assembly
lance locking bar
electric motor, complete with gearbox and brake
limit switches
terminal boxes
Basic Design Data
Arm radius ................................................................................................ 1150 mm
Approximate weight of one (1) lance ........................................................... 650 kg
Radial working travel ...................................................................................... 150o
Rotational speed .........................................................................................1.2 rpm
Number of operations per day .................................................. 1 or when required

3.7.2 Reference Drawings

2X00680.F2-M100-C001 Facility Layout, Key Plan

2X00680.F2-M100-C002 Facility Layout, Section A-A
2X00680.F2-M100-C003 Facility Layout, Elevation
2X00680.F2-M100-C004 Facility Layout, Plan at Pits El. 0.00
2X00680.F2-M100-C005 Facility Layout, Detail Plans
2X00680.F2-M100-C012 Facility Layout, Injection Lance Hoist, General Arrangement
2X00680.F2-M100-C013 Facility Layout, Lance Loading Arm, General Arrangement
2X00680.F2-M620-C001 Lance Loading Arm Assembly
2X00680.F2-M620-C002 Lance Loading Arm Assembly (opposite hand)

3.7.3 Components

Per material list Dwg. No. 2X00680.F2-M620-C001 and 2X00680.F2-M620-C002.

Bill of material includes such key components, as:
electric motor, complete with gearbox and brake
bearings
limit switches

3.7.4 Work Distribution

Basic engineering by Danieli Corus.

Detail engineering by Danieli Corus.
Supply and manufacturing by Danieli Corus.
On-site installation by CSH.

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4. PIPING SYSTEMS

4.1 Description

The piping systems for the hot metal desulphurization plant and de-dusting system are categorized
as follows.

4.1.1 Process Piping - Reagent Transport

Reagent transport piping from the lime truck and super sack to the storage silos,
transporters, dispensers and injection lance.

4.1.2 Nitrogen Piping

Nitrogen piping include following areas:

Lime truck unloading
Reagent conveying from transporter to dispensers
Dispenser conveying from dispenser to injection lance
Reagent storage silo dust collector pulse cleaning
Nitrogen supply for baghouse de-dusting system pulse cleaning
Nitrogen supply for the pneumatic valve actuators

4.2 Design Criteria

4.2.1 Process Piping – Reagent Transport

The reagent transport, piping design parameters are as follows:

MAGNESIUM DATA
The magnesium to be transported will be fed into the process via nitrogen pressure.
Magnesium Bulk Density (Aerated) ........................................................ 881 kg/m3
Magnesium Bulk Density (De-Aerated) ................................................ 1120 kg/m3

Note:
The magnesium is a hazardous material and explosions are possible from both the dust
and hydrogen.
The magnesium contains 10% lime or alumina.
LIME DATA
The transported lime will be fed into the silo via nitrogen pressure.
Lime Bulk Density (Aerated)................................................................... 881 kg/m3
Lime Bulk Density (De-Aerated) ........................................................... 1041 kg/m3

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Use pipe bends having 1.0 m (36º) bend radius (minimum) in lieu of standard elbows. The number
of pipe bends in reagent transport system must be kept to a minimum when routing pipe to
minimize abrasion and pressure loss.
Use 45º laterals in lieu of standard tee branch connectors.
All lime transport line elbows and pipe connections are to be flanged connections to allow for ease
of replacement and clean-out in the unlikely event of plugging.
Route reagent transport piping vertically and horizontally only (no sloped lines).

4.2.2 Nitrogen Piping

The nitrogen piping design parameters are as follows:

Design pressure (kPa) ...................................................................................... 900
Temperature (ºC) ....................................................................................... 0 to 30
Oxygen Contact ..............................................................................................0.1%
Dew point .......................................................................................................-40ºC

4.3 Materials

4.3.1 Process Piping - Reagent Transport

Pipe:
Seamless black carbon steel schedule 80, or equivalent, selected from, the following:
API 5L Gr. B seamless, or equivalent
ASTM A53 Gr. B seamless, or equivalent
ASTM A108 Gr. B seamless, or equivalent
Flanges:
150# Raised faced, weld neck, or equivalent
150# Slip on equivalent to ASTM A105 Gr. B, or equivalent
Fittings:
2 ½” butt weld, schedule 80, ASTM A234 WPD, or equivalent
2” & smaller socket welded, 3000#, ASTM A105, or equivalent
Fittings must have wall thickness equal to or greater than pipe wall thickness.
Gaskets:
3 mm thick ring type non-asbestos

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4.3.2 Service Piping

Nitrogen
Pipe:
Seamless black carbon steel Schedule 80, or equivalent, selected from, the following:
API 5L Gr. B seamless, or equivalent
ASTM A53 Gr. B seamless, or equivalent
ASTM A106 Gr. B seamless, or equivalent
Unions:
300# socket Weld, ASTM A105, or equivalent
Fittings:
Socket welded, 3000#, ASTM A105, or equivalent
Fittings must have wall thickness equal to or greater than pipe wall thickness.

4.4 Cleaning and Testing Requirements

4.4.1 Process Piping - Reagent Transport

The following cleaning and testing is recommended for the reagent transport piping systems:
remove all loose scale etc., by nitrogen blow-out
pressure test with nitrogen at 1.5 times operating pressure
final flush with nitrogen and seal until connections to equipment to be made
ensure proper isolation of all equipment prior to testing

4.4.2 Nitrogen Piping

The following cleaning and testing is recommended for the nitrogen piping:
remove all loose scale etc., by nitrogen blow-out
pressure test with nitrogen at 1.5 times operating pressure
final flush with nitrogen
ensure proper isolation of all equipment prior to testing

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4.4.3 Work Distribution

Basic engineering by Danieli Corus

Detail engineering by CSH
Construction, installation, cleaning, and testing by CSH

5. PULPIT AND EQUIPMENT ROOMS

This section is intended as a guideline to provide information and references in order to assist
CSH to execute the detail engineering, design and construction of the facility rooms.

5.1 Scope of Work

All facility rooms will be provided by CSH in accordance with the attached Basic Engineering
reference drawings.

5.2 Climate Control

5.2.1 General Requirements

The HVAC (heating, ventilation and air conditioning) systems will be designed and supplied in
accordance with the heat loads generated by all electrical equipment to be located within the room.
Design calculations shall also consider the following:
heat gain/loss through room enclosures
heat gain/loss due to pressurization air and/or leakage (doors, windows, etc.)
heat gain/loss due to lighting and building services
heat gain due to radiation from ladle and slag pot

5.2.2 Design Criteria

The following criteria are recommended as a basis for HVAC design, however may be utilized at
the discretion of CSH.

5.2.2.1 Control Room and LECO Analyzer Room

Minimum temperature ..................................................................................... 18ºC

Maximum temperature.................................................................................... 24ºC
Maximum rate of temperature change ..........................................................1ºC/hr
Relative humidity range .......................................................................... 40%-60%
Maximum rate of humidity change .................................................................5%/hr
Maximum particulate concentration.............................................................5 g/m3
Maximum HCl concentration ...................................................................... 2 g/m3
Maximum H2S concentration .................................................................... 4 g/m3
Pressurization (above atmospheric) .................................................... 10mm W.G.
Air change rate ............................................................................. 1m3/min/person

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 Expected heat load due to
Electrical equipment listed above .................................................................... 2 kw

5.2.2.2 Electrical Room

(Contains Low Voltage Distribution System, PLC, VFD, etc.)

Minimum temperature .................................................................................... 10ºC
Maximum temperature.................................................................................... 24ºC
Maximum particulate concentration............................................................ 5 g/m3
Maximum HCl concentration ....................................................................30 g/m3
Free moisture ................................................................................................. none
Pressurization (above atmospheric) .......................................................6mm W.G.
Air change rate ............................................................................. 10 air change/hr
Expected heat load due to
Electrical equipment listed above ................................................................... 7 kw

5.3 Reference Drawings

Dwg. No. Description
2X00680.F2-M100/C001 Facility Layout, Key Plan
2X00680.F2-M100/C002 Facility Layout, Section A - A

5.4 Work Distribution

Basic engineering by Danieli Corus

Detail engineering by CSH
Construction by CSH

6. PROCESS CONTROL (INSTRUMENTATION/AUTOMATION)

This section is intended to use as a guideline to provide information and references in order to
assist CSH to execute the detail engineering, design, and installation of the facility instrument and
automation systems.

6.1 Instrumentation

All necessary facility instruments to be supplied are itemized on the attached instrumentation list.
The scope of supply responsibilities for Danieli Corus and CSH are further identified on this list.

6.1.1 Danieli Corus Scope of Supply

Danieli Corus will provide the following:

Basic Engineering

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 Piping & instrumentation Diagram (P & ID)
Instrumentation list
Instrumentation location drawings
Instrumentation installation details
Specifications for all instruments
Equipment Supply
The following subsections cover the instrumentation to be supplied by Danieli Corus:

6.1.1.1 Nitrogen Supply Station:

Includes all instrumentation and manual valves in the 900 kPag line, downstream the pressure
reducing valve marking the battery limit. Please refer to drawing 2X00680F2-R215-E001A and
instrument list for details. Instruments will be shipped loose for Customer installation.

6.1.1.2 Silos Instrumentation:

Includes all instruments and manual valves, as shown in drawings 2X00680F2-R215-E001A (lime
silo) and 2X00680F2-R215-E003A (magnesium silo). Instruments will be shipped loose for
Customer installation.

6.1.1.3 Transporters Instrumentation:

Includes all instruments and manual valves, as shown in drawings 2X00680F2-R215-E001B (lime
transporter) and 2X00680F2-R215-E003B (magnesium transporter). Instruments will be installed
and wired to junction boxes in the transporter skid.

6.1.1.4 Dispensers Instrumentation:

Includes all instruments and manual valves, as shown in drawings 2X00680F2-R215-E002 (lime
dispenser) and 2X00680F2-R215-E004 (magnesium dispenser). Instruments will be installed and
wired to control panels in the dispenser frame.

6.1.1.5 Injection Stations:

Includes all instruments and manual valves, as shown in drawings 2X00680F2-R215-E005 (station
# 1) and 2X00680F2-R215-E006 (station # 2). Valves will be shipped loose for Customer
installation; lance hoists and loading arm limit switches will be pre-installed in the hoist frame.
The temperature measuring system is also supplied, including the indicator/processing units,
remote display and indicating lights, lance connection accessories and internal compensating
cable, 1800 temperature reading probes and 1800 temperature and sampling combined probes.
This system will be shipped loose for Customer installation.

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6.1.1.6 Baghouse System:

Includes instruments and manual valves, as shown in drawings 2X00680F2-R215-E008,

2X00680F2-R215-E009 and 2X00680F2-R215-E010. Instruments will be shipped loose for
Customer installation. Please refer to instrument list for details.

6.1.1.7 Hot Metal Sulphur Analyzer:

Includes the analyzer unit, furnace, operating computer and balance, as well as consumables for
500 samples. This system will be shipped loose for Customer installation.

6.1.2 Customer Scope of Supply

In general, it is the Customer responsibility to supply all the instruments not mentioned above, as
well as the engineering and accessories for the installation of the instrumentation shipped loose.
These requirements are detailed in the following subsections.
1. Detail engineering for all field installed instruments, supplementary to the installation details
provided as part of this package.
2. Calibration and connection to control system of all instruments.
3. Supply, installation and connection of all associated impulse, sample and pneumatic piping,
field cables and supports, and all other necessary materials for proper installation.
4. Supply of pressure reducing valve and booster tank to guarantee a 900 kPag nitrogen
supply to the plant. Please refer to drawing 2X00680F2-R215-E001A for details.
5. Supply, installation and connection of limit switches for the ladle car position, as well as
connection to the existing ladle weighing system and ladle car movement control. Please
refer to drawings 2X00680F2-R215-E005 and E006 for details.
6. Supply, installation and connection of dampers for each desulphurization station and
pouring pit, as well as isolating dampers for the existing and new baghouse systems.
Please refer to drawings 2X00680F2-R215-E007 for details.
7. Supply, installation and connection of level switches for each baghouse module hopper.
Please refer to drawings 2X00680F2-R215-E008 and E009 for details.
8. Supply of temperature reading probes (Heraeus Electro-Nite part # TC101315) and
temperature and sampling combined probes (Heraeus Electro-Nite part # CSW75S1500)
for plant operation beyond the original Danieli Corus supply, as well as the compensated
cable for connection between the indicator and the probe units (please refer to Section 7
for details).
9. Supply of consumable items and accessories for plant operation beyond the original Danieli
Corus supply (see section 6.1.1.7) of the hot metal sulphur analyzer. Please refer to the
manufacturer (Leco) documentation, to be included in the Maintenance Manual.

6.1.3 General Requirements

The contractor shall supply and install all impulse-piping, pneumatic tubing, valves, fittings
and supports, according to applicable standards and regulations.

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 All instrumentation wiring and cabling shall be tagged and marked per Danieli Corus
provided P & ID drawings and wiring diagrams. For cable voltage level segregation, refer to
section 7.
All necessary mounting hardware, bolts, nuts, u-bolts, washers, etc. shall be stainless steel
for impulse tubing and sample tubing.
Nitrogen, which is clean and dry, is the medium used for supplying instrument pneumatic
power to automatic valves and is denoted as “IA” on all P&IDs.

6.1.4 Instrument Locations

All facility instruments will be installed in the following areas (refer also to instrument location
drawings for details):
Main nitrogen supply station
Lime storage silo
Magnesium storage silo
Lime transporter (all instruments are pre-installed and pre-wired to terminal box)
Magnesium transporter (all instruments are pre-installed and pre-wired to terminal
box)
Lime dispenser (all instruments are pre-installed and pre-wired to control panel-
remote I/Os)
Magnesium dispenser (all instruments are pre-installed and pre-wired to control
panel-remote I/Os)
Lance hoists (limit switches and encoders pre-installed with mechanical equipment,
limit switches pre-wired to terminal box)
Baghouse area

6.1.5 Reference Drawings

Dwg. No. Description
2X00680F2-R216-E001 Configuration Diagram
2X00680F2-R215-E000 Symbols Legend Piping & Instrument Diagram
2X00680F2-R215-E001A Lime Storage Silo - P&I D
2X00680F2-R215-E003A Magnesium Storage Silo- P&I D
2X00680F2-R215-E001B Lime Transporter - P&I D
2X00680F2-R215-E003B Magnesium Transporter- P&I D
2X00680F2-R215-E002 Lime Dispenser – P&I D
2X00680F2-R215-E004 Magnesium Dispenser –P&I D
2X00680F2-R215-E005 Station No.1 Injection Area- P&I D
2X00680F2-R215-E006 Station No.2 Injection Area- P&I D
2X00680F2-R215-E007 Fume Dedusting Emission Control – P&ID
2X00680F2-R215-E008 Fume Dedusting Baghouse North – P&I D
2X00680F2-R215-E009 Fume Dedusting Baghouse South – P&I D
2X00680F2-R215-E008 Fume Dedusting Extraction Fans - P&I D
2X00680F2-Q203-R001/165 PLC I/O Schematics
2X00680F2-R215-C001 Instrument General Locations, Facility Partial Plans
2X00680F2-R215-C002 Instrument General Locations, Section A-A & Details
2X00680F2-R215-C003 Instrument General Locations, Silos Plans and Sections

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 2X00680F2-R215-C004 Instrument General Locations, Dispensers
2X00680F2-R215-C005 Instrument General Locations, Baghouse
2X00680F2-R215-C006 Dampers Plan View
2X00680F2-R215-C007 Dampers Section H-H
2X00680F2-R215-G000 Typical Installation Details, Drawing Index
2X00680F2-R215-G001 Typical Installation Details, Process Shut-off Valve
2X00680F2-R215-G002 Typical Installation Details, Oxygen Analyzer
2X00680F2-R215-G003 Typical Installation Details, Moisture Analyzer
2X00680F2-R215-G004 Typical Installation Details, Pressure Transmitter
2X00680F2-R215-G005 Typical Installation Details, Flow Transmitter
2X00680F2-R215-G006 Typical Installation Details, Pressure Regulating Valve (3 sheets)
2X00680F2-R215-G007 Typical Installation Details, Pressure Gauge
2X00680F2-R215-G008 Typical Installation Details, Level Switch
2X00680F2-R215-G009 Typical Installation Details, Nitrogen Blanketing Flow Switches
Document No. Description
2X00680F2-R215-F001 PLC I/O List
2X00680F2-R215-F002 Instrument List

6.2 Automation System

6.3 Scope of Work

Danieli Corus will provide automation system hardwire and software for the CSH hot metal
desulphurization stations project.

6.3.1.1 Danieli Corus will provide the following:

Detail engineering of the automation/control system. This includes:
Functional description
Software programming code
Operator interface screens
In-house simulation and testing
Software and screens documentation
Specifying and purchasing control system hardware
Commissioning of the control system
Cables and connectors for the communication of the system components (level 1
only).
Design and Supply the following equipment:
One (1) Main PLC Cabinet, containing the Siemens S7 414-2 processor, CP-343
communication processor and S7-400 I/O modules
One (1) Silo remote I/O cabinet, containing ET 200 remote I/O for connection and
control of silo area instrumentation.
Two (2) Dispenser remote I/O cabinets, each containing ET 200 remote I/O for
connection and control of dispenser instrumentation. One cabinet contains OP270
operator panel.

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 One (1) MCC remote I/O cabinet, containing ET 200 remote I/O for connection and
control of MCC and baghouse area instrumentation.
Each cabinet will also contain communication modules for Profibus DP network
communications with main PLC.
One (1) operator workstation, consisting of one (1) dedicated PC running Rockwell
RSView software.
One (1) level 2 server, consisting of one (1) dedicated server computer running the
desulphurization model and the historical database.
One (1) level 2 client, consisting of one (1) dedicated PC running custom software
for the level 2 HMI.

6.3.1.2 CSH will provide the following:

External interconnection wiring for all panels and instrumentation (except those pre-wired)
Connection of communication cable from PLC to distributed I/O
Detailed installation engineering drawings
Supply and installation of fiber optic connection between the control pulpit and the location
of the level 2 server.
Engineering, supply and installation of communication interface between the
desulphurization plant system and other computer systems existing in the facility.

6.3.2 Design Criteria

The equipment has been selected to meet the needs of the facility operation and client
preferences. Control systems are specific-purpose designed with respect to the process
requirements.
The selection for Siemens PLC architecture is based on availability in the world market. This
allows CSH to purchase replacement parts locally. Siemens hardware and software is of the
highest reliability and flexibility. Siemens distributed I/O, located at close proximity to major
equipment, significantly reduces the amount of field wiring that would be required to wire back to a
central PLC cabinet.
Normal operation of the facility will be controlled by PLC, via an HMI running in the operator work
station. The workstation communicates to the PLC through an Ethernet switch and a
communication processor. The pulpit operator may view and initiate any function from the
workstation. Local, manual operation can be performed via local control stations (for most
mechanical equipment) and OP270 panels (for silos, transporters and dispensers).
Refer to the Functional Description for detailed information regarding control system sequencing.
Each of the PLC Cabinets contains the I/O that is local to that station. Refer to paragraph 6.2.3 for
the breakdown.

6.3.3 Cabinet Locations

Main PLC Cabinet

Located in the control pulpit, contains connections and controls for the following equipment:

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 Injection lance hoists
Injection lance loading arms
Temperature/sample lance hoists
Ladle cars
Pouring pits and desulphurization stations fume collecting hoods
Local/remote selector cabinet
Silo PLC Cabinet
Located at the silo platform, contains I/O connections for the following equipment:
Lime storage silo
Magnesium storage silo
Nitrogen system
Lime transporter
Magnesium transporter
Lime Dispenser PLC Cabinet
Located at the Lime Dispenser, contains I/O connections for the following equipment:
Lime dispenser vessel
Magnesium Dispenser PLC Cabinet
Located at the Magnesium Dispenser, contains I/O connections for the following equipment:
Magnesium dispenser vessel
MCC PLC Cabinet
Located at the MCC, contains I/O connections for the following equipment:
Motors
VFD
Baghouse modules, conveyors and related equipment
Fume extraction fans

6.4 Testing and Pre-Commissioning Requirement

The Contractor will provide performance testing and calibration services, and make necessary
adjustments to equipment and facilities per Instrumentation Installation Manuals provided by
Danieli Corus.
All equipment/systems will be tested prior to energising and commissioning with suitable test
equipment. All test results to be recorded and submitted to Danieli Corus for review and records.
Meggers will not be used on electronic/sensitive circuitry.
Electric Arc welding shall not be permitted during or after equipment installation due to equipment
failure caused by grounding loops or high voltage transient spikes. The most susceptible
components are encoders and weighing systems.
The contractor will ensure adequate safety precautions are observed when testing equipment.
CSH procedures for safety lockouts, tagging, etc. must be followed.

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6.5 Standards and Specifications

The applicable standards and specifications (latest editions and revisions) from the following
institutions shall form part of this specification:
ISA Instrumentation, Systems and Automation
IEEE Institute of Electrical & Electronic Engineers
IEC International Electrotechnical Committee
NFPA National Fire Protection Association
NEMA National Equipment Manufacturers Association
Local Electrical Code

7. ELECTRICAL SYSTEMS

This section is to provide guideline information and specifications to assist CSH to execute detail
engineering design and installation of electrical equipment. The detailed design and installation by
CSH will provide proper grounding and cabling to ensure personal safety, protection of the
equipment, and smooth operation.

7.1 General Information

7.1.1 Standard:

NEC – National electrical Code

IEC – International Electrotechnical Committee
Local Electrical Code

7.2 Working Scope

7.2.1 Danieli Corus Inc will provide following:

Basic Engineering:
Single line diagram and load calculation.
Motor Control Schematics.
I/O Schematics.
Electrical Equipment Basic Locations.
Panel layout drawings and wiring diagrams.
Level 1 and level 2 system configuration.
Detailed Engineering and Equipment Supply:
Items are listed on the following table.

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 Table 8.1 Detailed Engineering and Equipment Supply by Danieli Corus

Ite Qty Name Description Location

m
1 1 Main PLC Cabinet Main PLC, Local I/Os Main control Pulpit
2 1 Silo I/O Cabinet Silo I/Os, Transporters I/Os Mag. Silo platform
3 1 Lime Dispenser Dispenser I/Os, Solenoid Valves Lime Dispenser frame
Control Cabinet OP270 Screen, (pre-installed and pre-
Weight Transmitter wired )
4 1 Magnesium Dispenser I/Os, Solenoid Valves Magnesium Dispenser
Dispenser Control Weight Transmitter frame (pre-installed and
Cabinet pre-wired )
5 1 MCC Remote I/O MCC I/Os, De-dusting System I/Os MCC room
cabinet
6 1 380V 50Hz MCC Low voltage motor starters and MCC room
breakers for de-sulphurization and De-
dust system
7 1 VFD Cabinets VFD unit and controls for injection MCC room
lance hoist
8 6 Local Control Selector switches, pushbuttons and Local to equipment –
Cabinets pilot lights injection hoists, T/s
hoists, lance arms
9 1 Main Pulpit Control Mode selector switches and E stop Main Control Pulpit
Consol push button
10 6 Local Pushbuttons Four (4) for rotary air lock valves, Local to equipment
one (1) for bag house conveyors,
one (1) for roots blower
11 3 E Stop Push Buttons Three (3) E stop pushbuttons Bag house east, bag
house west and
extraction fan area
12 6 Terminal Boxes Terminal boxes for injection lance Pre-installed and pre-
hoists, temperature/sample lance wired to limit switches
hoists, and lance changing arms
13 4 Terminal boxes Instrumentation for transporters Pre-installed and pre-
wired to instrumentation
14 2 AUMA MATIC Extraction fan No.1 inlet damper and Pre- installed on the
control units Extraction fan No.2 inlet damper damper actuators
controls
15 8 Bag house module Bag house module control sequence On each bag house
control panels board and pressure switches module
16 1 4160V 50Hz Motor Motor starters for fume extraction fans MCC room
Control

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7.2.2 CSH Will Provide Following

Detail Engineering and supply of

One (1) UPS installed at MCC room.
Main Pulpit Computer Desks
Two (2) control units for pouring pit hood damper actuators
Two (2) control units for desulphurization hood damper actuators
Two (2) control units for main bag house and existing stack bypass dampers
One (1) Power Distribution Panels PP-02
Installation of all electrical equipment
Design, supply and installation of all interconnection cables and cable raceways
Termination of all electrical equipment
Grounding System.

7.3 Grounding Requirement

7.3.1 General

The grounding system of the existing building and new installations should satisfy the following
three essential requirements:
Personal Safety
This defines the cross section of Protective Ground Bars (PGB) to limit touch voltages to
safe levels under fault conditions.
Lightning Protection
This defines the structure of the grounding electrodes buried in the soil.
EMC Design
This defines the details of how the various items of plant are grounded and interconnected.

7.3.2 Panels, Line-up

Figure 1 shows the grounding system for new construction. Figure 2 shows the grounding for new
panels installed in the existing building. These systems comprise the following components:
Buried ground Networks (BGN).
Ground Network Risers (GNR).
Floor Ground Grid (FGG) or Local Ground Point (LGP).
Line-up of Electrical Panels (LEP).
Protective Ground Bar (PGB) per Equipment Line-up with a minimum of 2 connections
between PGB and Floor Ground Grid (or Local Ground Point) to give personal safety.
Extra high frequency cable (HFC – 35mm cross section welding cables with very high
surface area and low inductance) connections to the floor Ground Grid (or Local Ground
Point), one every second panel within the line-up to ensure high quality performance.
All Signal Grounds (SG), Cable Shields (DG), and Protective Grounds (PG) are common
within a cubicle/panel)

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 Figure 1 – Electrical Panel Grounding – new installations EMC

Figure 2 – Electrical Panel Grounding – Modernisation EMC

7.3.3 Variable Frequency Drives

This system minimises EMC radiation by using either armoured cables or non-armoured cables in
metallic ducts or conduits. The circuit also minimises PWM Currents in the motor’s ground by the
“4”th return path direct to the PWM drive. See Figure 3.

Figure 3 – Variable Frequency Drive

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The main features of this installation are:
The transformer has an Electrostatic Shield.
The transformer solidly grounded on secondary.
Each item of plant has a direct Protective Ground, each linked via grounding grid return
path.
Approved cables types are used for transformer and motor connections, see figure 4.
Continuous Connection “5” from Motor to Load (to eliminate occurrences of shaft and
bearing current)

Figure 4 – Approved cable Types

7.3.4 Analog Devices (4-20 mA Loop)

Single twisted pair cable must have an overall shield and multi-pair must have an overall
shield with a shield over each pair.
The inner and outer shields will be grounded at one end to the local equipment protective
Ground Bar
A separate PGB connection must exist in parallel along the network to carry the ground
fault current.

7.3.5 Encoders

Use cables with individually shielded twisted pairs, plus overall shielded.
Ground the shields at source end termination point to the Local Protective Ground.
Use an insulated coupling or insulated ground link for overhung encoders.

7.3.6 Tanks and Transport Lines

All metal tank and transport line expansion joints and flexible connections shall be jumpered using
a flexible, copper braid, rigidly attached on either side with mechanical ‘toothed’ type clamps to
ensure proper ground continuity.
Each metal tank or metal transport line should have multiple connections to ground via thermo-
welded, copper cables.

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 Note:
All other exposed, non-current carrying metal parts or enclosures of electrically
connected equipment is to be grounded according to local code.

7.4 Cable Installation

The different criteria that must be taken into account in the installation of cables are:

The type of signal conveyed.

The segregation requirements for electromagnetic interference.
The cabling rules and practices
The operating and installation conditions

7.4.1 Cabling Segregation Category

The following classifications establish four Low Voltage segregation categories –levels A, B, C1
and C2, and one High Voltage segregation category – D
Level A – Analogue Circuit such as reference and measurement signals (24 V and 20 mA),
instrument loop signals (4-20mA), Encoder measurement signals and sensor power
supplies, communication cables.
Level B – Monitoring and control circuit, PLC Digital I/O signals and control power supplies.
Level C1 – normal AC (50 HZ, below 600 V) or DC power circuit such as power distribution
circuit, lighting circuit and fixed speed motor power supplies.
Level C2 – power circuits greater than 1kW operating at 600V or less, derived from
chopping type power supplies, typically, variable speed motor power supplies.
Level D – high voltage AC or DC power circuit (voltage greater than 600 V)

7.4.2 Basic Wiring Rules

Never mix conductors of different signal levels within the same cable or conduit.
Use at least one “Common” polarity conductor per cable for digital I/O logic switching
signals.
Ensure that the return wire of a signal pair is twisted with feed wire.
Use shielded cables for all signals of level A
Use separate cable trays for different segregation categories or tray barriers if two levels
installed in one common tray. The separation distances will be per local code.

7.4.3 Operating and Installation Conditions

Parameters should be taken into considerations are:

Rated voltage.
Rated current.
Type of cable construction.
Laying method.
Characteristics of the environment.

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7.4.4 Cable Specifications

Cables connecting VFDs and motors refer to section 7.3.3.

Cables for analogue signals refer to section 7.3.4
Cables for connecting temperature probe (on T/S hoist) and temperature
analyzer/transmitter (at Main Pulpit) shall be Compensating Cable, Nepra Insulated, Cu-
CuNi, Heraeus Part No. LC 33024002
Profibus Cable – connecting PLC and remote I/Os, refer to configuration drawing
2X00680F2-R216-E001 (cable supplied by Danieli Corus)
Ethernet Communication Cable – connecting PLC and HMI, refer to configuration drawing
2X00680F2-R216-E001 (cable supplied by Danieli Corus)

7.5 Power Distribution

7.5.1 Medium Voltage Distribution System

The 4160 V, 50Hz, 3 phase power system is employed for the extraction fan motor control. The
medium voltage motor controls will comprise a main incoming fused disconnect switch and two
motor starters.

7.5.2 Low Voltage Power distribution System

The desulphurization station and de-dusting system will be equipped with a 380 V, 50Hz, 3 Phase,
4 Wire MCC. The MCC will comprise a 600 A main incoming breaker, a main horizontal bus
construction rated for 600A continuous duty @ 50kA interrupting capacity. All connected loads will
be protected and or controlled by MCC mounted breakers or combination starters.
The 220 VAC control power will be simply getting from one phase line and one neutral line. The
neutral should not be connected to the MCC protection ground.
Details refer to single line diagram Q203-U001
The incoming feeder supply to the MCC will be supplied by CSH.
The principal operating voltages of the distribution system are described below.

Main Power 380VAC, 3F , 50Hz: Low voltage 3 phase motors power supply, drives and
power supply to UPS

Auxiliary Power 220VAC: Receptacles, lighting panels.

UPS control power 220 VAC: Control power distribution panel, power supply to
Level 1 and level 2 HMI computers, power supply to
main PLC cabinet and remote I/O cabinets.

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 Control Power 110 VAC Control power for motor starters, local and remote
I/Os, instrumentation

Direct Current - 24VDC: Instrumentation power supply. 24 VDC power supplies

will be provided at each PLC Cabinet and these will
provide power to the PLC components and to field
devices as required.

7.5.3 Electrical Room

Detail design, supply and construction of the electrical room will be by CSH. In addition to the
MCCs, the electrical room for will also house the following equipment:
Two (2) 380V AC variable frequency drive control package for Injection Lance Hoist
motors.
One (1) 220V AC Distribution Panel (PP-02), will provide auxiliary power for equipment that
does not require 220VAC conditioned power. The 220V AC distribution panel will supply,
but not be limited to, the following:
--220V AC power receptacles.
--Utility power for PLC cabinets.
Detail design, supply, installation and connection of the system will be by CSH.
One (1) 10 kVA UPS unit, will feed conditioned power distribution panel PP-01.
Detail design, supply, installation and connection of the unit will be by CSH.
One (1) 220V AC Conditioned Power Distribution Panel (PP-01), will provide power to the
process control equipment. The panel will supply the following:
PLC power supplies
PLC I/O modules
Operator work station
All instruments and valves for injection system ( 110 VAC Via PLC panels)
The installation and connection of the system will be by CSH.
One (1) MCC Remote I/O Cabinet, Danieli Corus will supply the cabinet and provide
detailed design. The installation and connection of the panel will be by CSH
7.6 Field Mounted Equipment

7.6.1 Remote I/O PLC Panels

Danieli Corus will design and supply the following remote I/O PLC cabinet:
One (1) Silo PLC Cabinet;
One (1) Lime Dispenser PLC Cabinet, with OP-270 installed in it for local operation
One (1) Magnesium Dispenser PLC Cabinets.

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7.6.2 Local Control Stations

The following field-mounted Control Stations/Cabinets will permit manual-local operation of

equipment and motors.
Two (2) Injection Control Stations
Two (2) Lance Changing control Stations
One (1) Lime Truck Unloading Control Station
One (1) Supersack Unloading Control Station
One (1) Main Pulpit Push Button Station
Three (3) E stop buttons at bag house area
Six (6) Pushbutton Stations for bag house local operation
The basic locations of these Local Control Stations are identified on Instrumentation location
drawings 2X00680F2-R215-C001 to C006. CSH will provide the necessary detailed installation
designs.

7.7 Take Over Point

Fume Extraction

CSH will design and supply the pouring pit and desulphurization hood dampers and actuators. We
recommend that the AUMA MATIC actuator control units should be used for the damper control.
The required input/output signals for the control unit Refer to P&ID drawing No.2X00680F2-R215-
E007, and I/O schematics drawings 2X00680F2-Q203-013, -014, -025, -026, -027, -028.

7.8 Reference Document

Drawings - See attached drawing list 2X00680F2-Q203-R002, C300.
Electrical Equipment List, document No. 2X00680F2-Q203-D003
380 V Motor List/Load Calculation Sheet, document No. 2X00680F2-Q203-B001
4160 V Motor List/Load Calculation Sheet , document No. 2X00680F2-Q203-B002

7.9 Design Criteria

Fixed Speed AC Motors Voltage ............................................................380V AC 3 50 Hz

Injection Lance Hoist ........................................................................................ 380V AC 3
Service Outlets Voltage .........................................................................220V AC 1 50 Hz
AC Control Voltage....................................................................... 220V/220V AC 1 50 Hz
Field-Mounted Sensor Voltage (Limit Switch, Pressure Switch) ............110V AC 1 50 Hz
PLC Discrete Input Voltage ...................................................................110V AC 1 50 Hz
.................................................................................................................................24 VDC
PLC Discrete Output Voltage .................................................................110V AC 1 50 Hz
PLC Analog Input ....................................................................................................24VDC
............................................................................................................................... 4~20 mA
PLC Analog Output ..................................................................................................24VDC
............................................................................................................................... 4~20 mA

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8. EMISSION CONTROL SYSTEM

8.1 System Description

The emission control system will remove and de-dust emissions generated by the desulphurization
process and hot metal transfer (from Torpedo car to Ladle) operation.
The emission control system consists of four (4) fume hoods, ductwork, four (4) motorized
balancing dampers, miscellaneous expansion joints, primary dust collector, baghouse and fume
extraction fans. The baghouse are equipped with rotary valves, screw conveyors, pneumatic
blower and dust silo for dust handling.

8.1.1 Fume Hoods

Four fume hoods are installed for the desulphurization and pouring operations in order to extract
the emissions that are generated. The fume hoods represent the discharge points.
The desulphurization (injection) hood is a canopy hood designed to minimize fugitive emissions
escaping out through the injection lance and temperature/sampling opening which is located on
the roof of the canopy hood. The design exhaust capacity for one desulphurization hood is
approximately 120,000 m3/h.
The pouring pit hood is a side suction hood located between the torpedo cars. The design exhaust
capacity for one pouring pit hood is approximately 290,000 m3/h.
There will be only one of the above four (4) hoods working at any given time.

Note:
The existing pouring pit hoods modification is not part of this project scope. The hoods
should be modified in order to guarantee the emission control of these two existing hoods,
including additional fume control measure.

8.1.2 Ductwork

The ductwork diameters are based on maintaining a velocity of approximately 20 m/s in the
ducting to prevent dust from settling out.
The exhaust rates from the transfer ladle hood and slag pot hood are to be balanced using the
motorized damper provided. Once set, there will not be any need to reposition the damper.

8.1.3 Primary Dust Collector (Existing)

See Compañia Siderúrgica Huachipato S.A. technical document.
The existing primary dust collector is to be modified to become a spark arrestor. The inside
contents have to be removed. A buffer plate is to be installed.

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8.1.4 Baghouse

The new baghouse will be pulse-jet type, which is the most suitable type for metallurgical dust.
The baghouse will have eight (8) independent compartments (modules) arranged in two blocks.
Each module is isolated by manual inlet and outlet dampers which will facilitate system
maintenance during normal operation.
Each module has three sections: clean air plenum, bag compartment, and bottom hopper. Filter
bags, sleeved on wire cages, are installed in a tubesheet separating clean air plenum from the bag
compartment.
The bags and cages will be installed in seven (7) compartments only. The eighth compartment will
be used in the future together with other two compartments as shown on layout drawings.
Process conditions:
Gas flow rate .................................................................................... 290,000 m3/hr
Max gas temperature.....................................................................................120 ºC
Baghouse design:
No of compartment ............................................................................................... 8
No of bags per one compartment ..................................................................... 256
No of cages per one compartment ................................................................... 256
Total filter cloth area ................................................................................. 3139 m2
Filter flow rate ............................................................................0.0257 m3/m2/sec
Bag size ...................................................................... 152mm dia x 3683 mm long
Bag material ....................................................................... 16oz polyester felt filter

8.1.5 Fume Extraction Fan

Two new fans will be installed to cover pressure loss of gas flow through the bag house and
associated ductwork. They are located outdoors and downstream of the bag house.
Operating condition:
Flow rate .......................................................................................... 145,000 m3/hr
Static pressure ............................................................................................ 6.3 kPa
Max. Operating temperature .........................................................................120 ºC

Brake horse power:

At 20 ºC ...................................................................................................... 312 kW
At 65 ºC ....................................................................................................... 306 kW
Motor
Installed power ............................................................................................ 331 kW
Speed ...................................................................................................... 992 rpm
Power supply ................................................................................4160V/3ph/50Hz

8.1.6 Dust Handling System

A screw conveyor system delivers the dust, which is dislodged from the baghouse bottom hopper,
to a pneumatic conveying pipeline to elevate dust into a storage. The storage silo will act as a

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surge accumulator which will be periodically discharged into a dust transport device (dump trailer)
for disposal.
Dust flow rate in screw conveyor (maximum) ....................................................160 kg/min
Dust flow rate in screw conveyor (average) .....................................................26.7 kg/min
Conveying air flow rate ....................................................................................... 745 m3/hr
Dust silo volume ....................................................................................................... 50 m3
Dust silo vent flow rate ..................................................................................... 1000 m3/hr

8.2 Reference Drawings

Dwg. No. Description
2X00680F2-M100-C001 Facility Layout, Key Plan
2X00680F2-M100-C002 Facility Layout, Section A-A
2X00680F2-M100-C003 Facility Layout, Elevation
2X00680F2-M100-C020 De-dusting Piping, Plan View
2X00680F2-M100-C021 De-dusting Piping, Section A-A
2X00680F2-M100-C022 De-dusting Piping, Section B-B
2X00680F2-M100-C023 Injection Hood, General Arrangement
2X00680F2-M284-C001 General Arrangement, Plant Layout
2X00680F2-M284-C002 General Arrangement, Elevation Views A-A and B-B
2X00680F2-M284-C003 General Arrangement, Elevation Views C-C, D-D and E-E

8.3 Definition of Emissions

The following definition of emissions is applicable to the hot metal desulphurization process using
lime/magnesium blends.
Emissions generated during the desulphurization operations include dust particulates,
predominantly oxides, lime and carbon, as well as a small amount of post-combustion gases.
The information of emissions generated during the pouring process is to be supplied by Compañia
Siderúrgica Huachipato S.A.

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8.3.1 Particulates

Quantity:
Approximate quantity of particulates generated during desulphurization operations:-
Desulphurization ............................................................ 0.25 kg/tonne hot metal
Composition:
Composition of particulates will change, based upon process conditions; however, the
following composition could be considered as typical:-
% by weight
MgO ................................................................................................................ 60%
CaO ................................................................................................................ 30%
Fe2O3 ............................................................................................................... 2%
Al2O3 ................................................................................................................ 1%
C ....................................................................................................................... 5%
Other ................................................................................................................. 2%
Size Distribution:
Particulate size distribution will also vary; however, the following could be considered as
typical:
Smaller than 44 microns ................................................................................... 1%
44 to 125 microns ........................................................................................... 60%
125 to 250 microns ......................................................................................... 30%
Larger than 250 microns ................................................................................... 9%

8.3.2 Gases

In addition to ambient air, fumes extracted from the facility will contain the following:

Nitrogen used as a transfer medium for the desulphurization reagent

(Approximate) ........................................................................... 10-25 Nm3/min
CO, CO2, and SO2 ................................................................. negligible amounts

Note:
Danieli Corus has no data available, nor are they aware of any tests which were
conducted to determine actual quantities of gases generated by the process.

8.4 System Design Parameters

The following parameters apply to the emission control system of one (1) desulphurization station
and one (1) pouring pit.

8.4.1 Fume Extraction Flow Parameters

Flow rate for desulphurization station (normal) ............................................ 120,000 m3/hr
Flow rate for pouring pit (maximum) ............................................................ 290,000 m3/hr

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 Operating temperatures (injection hood only):
Nominal ........................................................................................................ 100°C
Minimum ........................................................................................................ 20°C
Maximum ..................................................................................................... 135°C
System flow resistance, calculated based upon flow temperature of 20°C:
Main duct (fume hoods to primary dust collector) ...................................... 1450 Pa
Max pressure drop across primary dust collector
(Approximation after modification) ..................................................... 500 Pa
Duct between primary dust collector and baghouse ................................... 300 Pa
Max pressure drop across baghouse ....................................................... 2500 Pa
Clean duct (baghouse to fan) ..................................................................... 370 Pa
Fan discharge and stack ............................................................................. 570 Pa
Total .......................... 5690 Pa

8.4.2 Baghouse Inlet Conditions (for Design)

Approximate dust concentration at the inlet to the baghouse:

Average ................................................................................................. 5.5 g/m3
Maximum ............................................................................................... 33.1 g/m3

Note:
The above concentration data are used for designing baghouse.

8.5 Disposal

8.5.1 Slag After Desulphurization

The slag skimmed after completion of the desulphurization process is not considered toxic.
It is generally treated in the same manner as the blast furnace slag.
The following is the typical composition of the slag before and after the desulphurization process.
Composition % Before % After
SiO2 18 11.7
A12O3 3.5 3.1
TiO2 0.9 0.67
P2O5 0.26 0.015
MnO 0.88 0.47
Na2O 2.45 1.7
K2O 0.06 0.055
C 21.4 23
CaO 4.1 9.2
MgO 1.3 2.8
S 1.36 3.8
FeO 32.4 32

8.5.2 Baghouse Dust

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The baghouse dust from the desulphurization process using magnesium/lime reagents is not
considered toxic. Since the dust contains only small amounts of iron units, it is typically disposed
into land-fill sites. Few companies pelletize the dust and charge it into a blast furnace.

8.6 System Performance Data

8.6.1 Hood Efficiency

The following is the anticipated injection hood collection efficiency:

Desulphurization ............................................................................................. 99%
Uncontrolled discharge to
Atmosphere (for injection hood only) ..................................... 2.5 g/tonne hot metal

8.6.2 Baghouse Emission

Collection efficiency .................................................................................................... 99%

Controlled discharge to atmosphere .................................................................. 20 mg/m3
Maximum particle size .......................................................................................10 microns

8.6.3 WORK DISTRIBUTION

Basic engineering by Danieli Corus.

Detail engineering by Compañia Siderúrgica Huachipato S.A.
Construction, installation and commissioning by Compañia Siderúrgica Huachipato S.A.
Refer to P&ID for work distribution in detail.

9. MATERIAL SAFETY DATA SHEETS

9.1 Lime

9.2 Magnsium

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