investments implementation in industry - dalselv design · 2017-03-07 · investments...
TRANSCRIPT
INVESTMENTS IMPLEMENTATION IN INDUSTRY
DALSELV DESIGN a. s. www.d-design.cz Slévárenská 403/11 phone: +420 596 633 121-2 709 00 Ostrava fax: +420 597 579 990
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DALSELV DESIGN a. s. PROFILE
Founded at a relatively short time ago, DALSELV DESIGN a. s. has showed it is built
on strong basis formed by long experience and deep expertise of its staff and
proactive approach to the execution of the different business transactions. The
experience of our staff in technology, organization and equipment installation make
the company a reliable, renowned and, most importantly, fair partner for investors,
cooperating companies and other entities in the market, in particular in the following
fields:
Primary metallurgy
§ sintering plants
§ blast furnaces
§ cokemaking plants
§ steelmaking plants
Raw material (coal and ore) processing plants Power plants and heating plants Input material (bulk material) storage, handling and preparation
§ cement works
§ quarries
§ sandpits
§ agricultural companies
The equipment for the fields above comprises:
§ Material conveyance lines
§ Machines for bulk handling operations
§ Sorting and crushing machines
§ Charge preparation (milling, mixing) machines
§ Treatment and shipment systems
§ Machine, wagon and car carriages
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§ Drive units and systems (chain and rope)
§ Pressureless and pressure piping systems and pipelines customized according
to the customer’s specifications (circular, shaped, special)
§ Pressure water pumping and distribution systems
§ Cranes and lifting gear
§ Equipment for breaking of frozen load on wagons
§ Transfer ladle and scrap cars
The equipment is, of course, provided based on turnkey delivery which includes a
solution ensuring compliance with emission limits and environmental requirements
including commissioning and handover to the customer.
DALSELV DESIGN a. s. employs experts who efficiently apply their experience and knowledge in the following fields:
§ Design and engineering of equipment
§ Management of production, deliveries and installation
§ Securing compliance with quality, environmental and safety requirements
§ Construction site management, design and installation supervision
§ Organization and management of complex testing
§ Equipment commissioning
§ Guarantee and after-guarantee service
DALSELV DESIGN a. s. designers, engineers and implementation specialists have
been involved in execution of many design, upgrading and greening orders from
Czech as well as foreign metallurgical plants and companies. The long-term
experience in the fields listed above is the most valuable asset of the company!
A factor of no less importance is the long-term cooperation of our staff with VŠB -
Technical University of Ostrava, especially with its Faculty of Mechanical Engineering
and Faculty of Metallurgy and Materials Engineering in arrangement of educational
events and development of solutions at theoretical, technical and visual levels.
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Other services provided by DALSELV DESIGN a. s.
§ Preparation of drawing documentation for external companies
§ Preparation of production documentation including 3D model based on design
documentation (steel structures, electrical substations, piping lines, machinery)
Specification of drawing documentation for external companies:
§ Preparation of detail design documentation of equipment for project – project
sections, project subsections, operating units.
§ The documentation shall consist of technical report, list of machinery and
equipment, process flow chart, painting specification, equipment assembly
drawing, layout drawing and sectional views.
§ The documentation shall include information for other contractors – steel
structure loading, civil engineering, wiring and I&C.
We shall provide the following based on the detail design documentation or 3D model:
§ Preparation of production drawing documentation (production assemblies and
subassemblies, shop production drawings, technical reports for production and
installation) for project sections, project subsections or operating units in
accordance with applicable ČSN standards
§ Preparation of operation and maintenance manuals, lubrication charts, lists of
spare parts, assembly of quality documentation, etc.).
The documentation can be prepared in:
§ Czech language
§ English language
CAD system applied: Autodesk Product Design Suite 2016.
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The drawings shall be printed in common ISO A0 to A4 sizes and the technical reports,
parts lists, lists of machinery and equipment, and painting specifications in ISO A4
size.
File formats:
§ Digital files shall be provided in “PDF” or “DWG” format.
§ Text files shall be provided in MS-Office or “PDF” format.
Quality system of DALSELV DESIGN a. s.
In order to maximize the service quality provided to our customers and minimize the
impacts on environment, energy consumption and human health our Design
Department and Realization personnel follow the quality management requirements
stipulated in four standards: ČSN EN ISO 9001:2009, ČSN EN ISO 14001:2005, ČSN
OHSAS 18001:2008 and ČSN EN ISO 50001:2012. The obtained certificates help
DALSELV DESIGN to achieve its objectives – customer satisfaction, environmental
protection, reducing energy consumption, health and safety.
The quality system in place, experience, high expertise and qualification of our
designers and realization personnel plus the application of state-of-the-art equipment
and technologies pave our company the way to successful operation in the local and
European markets.
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We are the member of the Czech Cokemaking Society
The innovative approach requires new knowledge, experience exchange and also
actual information in the science and research. That is why not only the company
DALSELV DESIGN but as well some of our individuals – the designers, project
engineers and other technicians and specialists are the members of the Czech
Cokemaking Society that associates the cokemaking specialists from the Czech
Republic and other countries and the Czech and foreign companies.
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BRANCH OF ACTIVITY PRESENTATION
COKEMAKING PLANTS
The industrial and especially metallurgical production needs coke for its specific
properties. The coke is manufactured in coke-oven batteries and their individual
coking chambers by heating of coal charge through heating walls to the temperature
of over 1000°C without contact with air.
These classic coke-oven batteries produce coke for:
§ Blast furnaces
§ Foundries
§ Special operations
§ Heating plants
§ Households
According to the type of input coal (composition) and other properties and expected
use the coke-oven batteries are operated in two versions:
§ with top charging operation
§ with stamped charging operation
The size of individual chambers (especially the height) and number of chambers
combined in blocks are selected according to the necessary production capacity. The
number of blocks of the coke-oven battery is given by the production time and other
conditions.
The biggest difference between the coke-oven batteries with top charging and
stamped charging operation consists in the way of transport of coal charge into the
coking chamber.
Top charging operation:
On the roof of the coke-oven battery there is the travelling charging car which
transfers the coal mixture from the coal tower into the bunkers of the charging car and
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then through the feeders and tight pipeline (telescopes) it charges it to the coking
chamber through the so-called filling openings. For the evenness of the charged coal
layer it is levelled with a device located on the pushing machine. This levelling forms
a space for removal (exhaust) of gases originating during the coking process (coal
heating and its carbonization and humidity evaporation) to other devices and through
the pipeline this raw coking gas is transported to the chemical part of the cokemaking
plant.
FIG. 1 – CROSS SECTION THROUGH COKE-OVEN BATTERY – TOP CHARGING OPERATION
Stamped charging operation:
In this operation the coal charge from the coal tower is transferred to the bunkers of
the stamping, charging and pushing machine travelling on the rails on the machine
side of the coke oven battery. In this machine there is a coal block formed by means
of the stamping device in the stamping box with dimensions necessary for correct
function during further coking procedure. This coal block is charged to the coking
chamber by means of the charging rod.
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FIG. 2 – CROSS SECTION THROUGH COKE-OVEN BATTERY - STAMPED CHARGING OPERATION
The above information implies that the coking plant does not mean only the coking
batteries, but includes also other complexes:
Charge preparation (coal service): § coal storage
§ grinding
§ mixing
§ transport to the coal tower
Coke quenching (predominantly wet) § quenching tower
§ quenching car
§ pump station
§ sumps and catchpits
Coke service § coke wharf for quenched coke
§ coke screening plants
§ coke treatment plants
§ products loading
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Chemical part of coking plant § cleaning and treatment of raw gas
§ heating gas preparation
- coking gas
- mixed gas
§ desulphurization of gas
§ chemical products treatment
In coke oven batteries the following types of refractories are used:
§ Classical refractories for premises with normal temperatures
§ Refractories for premises with high temperatures
Connection, interconnection and coherence are ensured by technological equipment
of steel structure type which provides for coherence and consistency of the shape of
refractory in cross as well as in longitudinal direction. Technological equipment further
contains not only special devices, for example doors, ascension pipes, collecting main,
special valves and fittings but as well pipeline systems for various media.
Mechanical-technological devices for both types of coke-oven batteries are similar or
even identical, of course depending on the size and dimensions of the chambers.
The biggest differences are in the operating machines that provide for operation of
the coke-oven batteries including environmental protection requirements for
operation.
Battery machines for top charging operations:
Pushing machine:
It travels along the coke-oven battery on the machine side and operates opening of
the door of the coking chamber, its cleaning and its subsequent closing.
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It further discharges the coke from the coking chamber, cleans the door and the door
frame, levels the coal in the chamber and carries out other activities associated with
the operation of the coke-oven battery and coking chamber.
The machine usually is of “single-spot positioning” design being able to carry out all
the operations associated with operation of the coking chamber from one machine
position.
FIG. 3 – PUSHING MACHINE
Coke guiding car:
It travels along the coke-oven battery on the coke side. Its main task is to transfer the
hot coke from the coking chamber to the quenching car. This activity is ensured by a
movement of pushing rod from the pushing machine and guiding cage on the coke
guiding car moved to the lining of the coking chamber which bridges over the
distance between the chamber and the quenching car. The devices of the guiding car
open the coking chamber door, clean the door and the door frame and after pushing
the coke out and return of the guiding cage to the initial position they close the coking
chamber. Apart from other auxiliary operations the activity of the coke guiding car is
also focused on the removal of hot air mass with the coke dust originating during coke
discharge and fall into the quenching car over the hood, pipeline and transfer system
to the dedusting station where the air mass is cleaned.
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Location of rails of the car and hence its dimensions and shape respects the technical
and environmental protection requirements, space possibilities, customer
requirements etc. The coke guiding car usually works with single-spot positioning on
the axis of the operated coking chamber.
FIG. 4 – COKE GUIDING CAR
Charging car:
It travels on the rails situated on the roof of the coke-oven battery, transfers coal from
the coal tower, removes the lids of the charging openings, fills the coking chamber
and replaces the lids of the charging openings. Other auxiliary operations and
activities are carried out by the charging car within the technological cycle - operating
(opening, closing) and cleaning the ascension pipes and hydro-injection valves.
According to the way of removal of the raw gas there are the coke-oven batteries with
two collecting mains and two rows of ascension pipes or with one collecting main and
one row of ascension pipes or with one collecting main and one row of ascension
pipes and one row of mini-ascension pipes for transferring charging gases to other
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chamber already charged earlier. This transfer is carried out by the transferring pipe
of charging gases which controls the lids of mini-ascension pipes and provides for
transfer of part of the charging gases from the chamber being charged. Charging cars
are of single-spot positioning design.
FIG. 5 – CHARGING CAR
The following is considered for all battery machines according to the needs,
requirements and experience of the customer:
§ Device positioning the machine to the operated chamber
§ Power supply
- wire trolley
- rigid profile trolley
- cable
§ Drives by means of hydraulic system
Battery machines for stamped charging operations
Stamping, charging and pushing machine:
It travels along the coke-oven battery on the machine side transferring the coal charge
to the bunker (for more chambers simultaneously) and stamps the coal block.
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It further provides for opening the coking chamber door, its cleaning, pushing coke
from the chamber and cleaning the door frame. After travelling and alignment of the
axis of the charging assembly with the axis of the operated coking chamber it charges
the coal block into the coking chamber and after further transfer it closes the chamber
with door.
The stamping, charging and pushing machine is equipped with further device carrying
out technological cycle and environmental friendly operation like:
§ sealing of the coal block
§ cleaning and removing the spilled coal (conveyor, bucket elevator)
FIG. 6 – STAMPING, CHARGING AND PUSHING MACHINE
Coke guiding car:
It is identical with guiding cars for top charging operation and is designed according
to space, technological and environmental protection requirements or regulations.
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FIG. 7 – COKE GUIDING CAR
Převáděcí vůz:
It travels on the rails situated on the roof of the coke-oven battery and carries out
technological-ecological operations.
It opens and closes the ascension pipes and flaps, operates hydro-injection, cleans
the ascension pipes and transfers charging gases to other chamber already charged
earlier. Further auxiliary activities are carried out by special equipment like
lifting/reassembling device for needs of maintenance of the car and battery roof,
vacuum cleaner of the heating flues etc.
FIG. 8 – TRANSFER CAR
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MACHINES FOR BULK HANDLING OPERATIONS
For handling and storing of various kinds of bulk materials there is possibility to make
use of several types of stockyard machines. Selection of the most convenient type
should consider:
§ storing
§ homogenization
Protection against atmospheric conditions:
§ outdoor stockyard
§ indoor stockyard
Volume of stored material – storing capacity
Number of stored material:
§ separately each grade
§ common storing
§ homogenization
Stored material properties:
§ type
§ granularity
§ humidity
§ adhesiveness
In order to be able to decide on the suitable type it is necessary to consider other
factors, for example:
§ stacking and reclaiming capacity
§ simultaneous stacking and reclaiming
§ shape and area of the stockyard
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After considering of all circumstances we can use the offer of several types of
stockyard machines:
Gantry belt stacker and Gantry bucket-chain reclaimer
FIG. 9 – GANTRY BELT STACKER
FIG. 10 – GANTRY BUCKET-CHAIN RECLAIMER
These machines are used for outdoor stockyards with the need of big capacity and
the best carried out homogeneity.
Here it is possible to stock various types of materials on individual piles and reclaim
them according to needs, or as it has been said, we can carry out controlled
homogenization of identical material from various suppliers or from various deposits.
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Machine capacities:
§ stacking 800 m³/hour
§ reclaiming 400 m³/hour
Stockyard – 50 m x 1000 m
Advantage of these stockyards is the mixing of the already stocked blend before
further use and saving of a part or entire equipment for blend preparation.
Gantry stacker/reclaimer
FIG. 11 – GANTRY STACKER/RECLAIMER
This is the combination of gantry belt stacker and gantry bucket-chain reclaimer into
one machine. This double-purpose machine provides advantages of individual
stackers and reclaimers but can be used only either for stacking or for reclaiming.
Machine capacities are approximately halfway compared to the separate machines.
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Side scrapers
FIG. 12 – SIDE SCRAPER
The big advantage of this type is using in the indoor stockyards for the possibility to
store material without influence of atmospheric conditions. The stockyard is formed
by longitudinal supporting wall both for placing of upper track and support the
stockyard structure. Between tracks in transverse direction the reinforcing walls serve
as boxes walls for storing of particular sorts of material.
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The storing capacity may be doubled by mirror design of the same equipment
situated on the opposite side of the supporting wall.
Different sorts of material are stacked by independent system of travelling and
reversible conveyors.
Reclaiming is made by the side scraper with capacity 350 m³/hour. This equipment
works in automatic mode according to selected program.
Semi-gantry stacker/reclaimer
OBFIG. 13 – SEMI-GANTRY STACKER/RECLAIMER
The semi-gantry stacker/reclaimer is used in similar way as in previous case with the
possibility of homogenization of the stacked material; the stacking is carried out by
the machine.
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This double-purpose machine is predominantly determined for high capacity outdoor
stockyards due to big dimensions of the stockyard structure without central
supporting.
The machine may be used only either as a stacker or as a reclaimer.
Bucket-wheel stacker/reclaimer
FIG. 14 – BUCKET-WHEEL STACKER/RECLAIMER
The piles of material are situated on both sides of the machine runway in whose axis
the feeding and removing stockyard belt conveyor with the possibility of continuous
transfer of material directly to bunkers is located.
By means of a set of conveyors and transfer points the material is stacked in a sickle-
shaped way or other way by selected program. Reclaiming is carried out by the
chamber-less wheel and chute on the jib reverse conveyor and then through the
transfer point on the stockyard belt conveyor. This double-purpose machine ensures
low degree of homogenization and enables either only stacking or reclaiming
Output capacity is approximately 1000 m³/hour.
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These basic types of machines for bulk handling operations are used in power plants,
metallurgical plants, cement plants and the like. It is possible to customize them in
compliance with safety and environmental protection aspects.
Complex solution not only for cokemaking plants
Our team is prepared to realize all your expectations
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REFERENCE LISTS
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MACHINES AND EQUIPMENT FOR COKEMAKING PLANTS
Customer Type Type of
operation
Chamber dimensions in
hot state Capacity Year of
commissioning, hand over
Note
width [mm]
height [mm] [m3]
TŽ Třinec,
Czech
Republic
Gas Transfer
Car COB
No. 11
Stamped
charging 430 3 645 19,2 2016 EPC delivery
TŽ Třinec,
Czech
Republic
Coke Guide
Car No. 2 COB
No. 11
Stamped
charging 430 3 645 19,2 2016
Complete reconstruction
TŽ Třinec,
Czech
Republic
Stamping,
Charging and
Pushing
Machine No. 8
COB No. 11
Stamped
charging 430 3 645 19,2 2016 EPC delivery
TŽ Třinec,
Czech
Republic
Stamping,
Charging and
Pushing
Machine No. 5
COB No. 12
Stamped
charging 430 3 645 19,2 2015
Detail Engineering of
partial reconstruction
TŽ Třinec,
Czech
Republic
Coke Guide
Car No. 1 COB
No. 11
Stamped
charging 430 3 645 19,2 2015
Detail Engineering of
partial reconstruction
TŽ Třinec,
Czech
Republic
Gas Transfer
Car COB
No. 11
Stamped
charging 430 3 645 19,2 2014 Detail Engineering
TŽ Třinec,
Czech
Republic
Coke Guide
Car No. 2 COB
No. 11
Stamped
charging 430 3 645 19,2 2014 Detail Engineering
Eregli Iron &
Steel Works
Company
(ERDEMIR),
KDZ. Eregli,
Turkey
Coke Oven
Batteries
No. 1÷3, By –
product plant
Top
charging 438 4 572 23,2 2014 Audit of existing stage
ArcelorMittal
Ostrava a. s.,
Ostrava,
Czech
Republic
Stamping,
Charging and
Pushing
Machines No.
31, 32, COB
No. 1, 2
Stamped
charging 430 3 645 19,2 2014
Technical assistance for
stamping boxes
measurements
evaluation and their
adjustment
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MACHINES AND EQUIPMENT FOR COKEMAKING PLANTS
Customer Type Type of
operation
Chamber dimensions in
hot state Capacity Year of
commissioning, hand over
Note
width [mm]
height [mm] [m3]
TŽ Třinec,
Czech
Republic
Coke Oven
Battery No. 11
Stamped
charging 430 3 645 19,2 2013 Detail Engineering
TŽ Třinec,
Czech
Republic
Stamping,
Charging and
Pushing
Machine No. 8
COB No. 11
Stamped
charging 430 3 645 19,2 2013 Detail Engineering
TŽ Třinec,
Czech
Republic
Stamping,
Charging and
Pushing
Machine No. 5
COB No. 12
Stamped
charging 430 3 645 19,2 2013
Reconstruction of steel
structure
Cokemaking
Plant
Svoboda,
OKK
Koksovny a. s.,
Ostrava,
Czech
Republic
Installation of
mini ascension
pipes with
reconstruction
of Gas Transfer
Car COB No. 8
Stamped
charging 515 3 500 23,97 2013 EPC delivery
Cokemaking
Plant
Svoboda,
OKK
Koksovny a. s.,
Ostrava,
Czech
Republic
Modernization
of reversing
equipment
COB No. 7
Stamped
charging 515 3 500 23,97 2012
Cokemaking
Plant
Svoboda,
OKK
Koksovny a. s.,
Ostrava,
Czech
Republic
Modernization
of reversing
equipment
COB No. 8
Stamped
charging 515 3 500 23,97 2012
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MACHINES AND EQUIPMENT FOR COKEMAKING PLANTS
Customer Type Type of
operation
Chamber dimensions in
hot state Capacity Year of
commissioning, hand over
Note
width [mm]
height [mm] [m3]
TŽ Třinec,
Czech
Republic
Coke Guide
Car No. 3 COB
No. 12
Stamped
charging 430 3 645 19,2 2011
Complete
reconstruction
TŽ Třinec,
Czech
Republic
Stamping,
Charging and
Pushing
Machine No. 7
COB No. 12
Stamped
charging 430 3 645 19,2 2011
Complete
reconstruction
TŽ Třinec,
Czech
Republic
Coke Guide
Car No. 1 COB
No. 12
Stamped
charging 430 3 645 19,2 2011 Partial reconstruction
TŽ Třinec,
Czech
Republic
Stamping,
Charging and
Pushing
Machine No. 5
COB No. 12
Stamped
charging 430 3 645 19,2 2011 Partial reconstruction
TŽ Třinec,
Czech
Republic
Gas Transfer
Car COB
No. 12
Stamped
charging 430 3 645 19,2 2011 EPC delivery
KK Zabrze
S.A. Radlin,
Poland
Ascension
Pipes Lid and
Frame Cleaner
Stamped
charging 450 5 070 2011
KK Zabrze
S.A. Radlin,
Poland
Coal Block
Cover
Stamped
charging 450 5 070 2010
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MACHINES AND EQUIPMENT FOR BULK HANDLING OPERATIONS
Customer Type Capacity
[t/m3] Material Bulk
density [t/m3]
Year of commissioning,
hand over Note
TŽ Třinec,
Czech Republic Gantry Belt Stacker
1 500
(at 2 t/m3)
sintering
mixture 0,5 ÷ 2,7 2015
Detail
Engineering,
coordination,
supervision
TŽ Třinec,
Czech Republic
Gantry Bucket
Reclaimer PN 1200
1 200
(at 2 t/m3)
sintering
mixture 0,5 ÷ 2,7 2013
Feasibility
study
TŽ Třinec,
Czech Republic
Gantry Belt Stacker
PZ 1500
1 500
(at 2 t/m3)
sintering
mixture 0,5 ÷ 2,7 2012
Feasibility
study
ANOTHER MACHINES AND EQUIPMENT
Customer Type Type of operation Capacity Year of
commissioning, hand over
Note
TŽ Třinec,
Czech Republic Disintegrator
Disintegration of frozen bulk
materials in wagons before
defrosting
1 wagon/
10 minutes 2014
Feasibility
study