project

Fumes capture system for scrap cutting station.

Project carried out for a large-scale steel plant, located in Spain and Portugal, and specialized in the production of long steel and derivatives.

This company is a leader in the scrap metal recycling sector and the manufacturing of products for the construction industry and other industrial sectors.

As part of our commitment to improving the efficiency and safety of your operations, we carry out several key tasks related to the installation, auditing and optimisation of smoke extraction and purification systems, as well as the improvement of extraction fans.

The project involved three main works , all aimed at improving the efficiency and functionality of smoke extraction and ventilation systems in different areas of the plant.

These works included the design of new extraction systems and audits to identify and resolve problems in smoke purification .

In the first job, a smoke extraction system was designed and installed in the cutting area of one of the plant’s facilities.

This system included a closed metal structure of approximately 8.50 x 3.75 meters, with a height of 3 meters, equipped with a suction hood at its top to capture the fumes generated during oxycutting operations .

The system was also connected to the main suction duct of the EAF canopy , thus ensuring efficient and safe extraction.

To support the structure, a 1-metre-high concrete perimeter wall was designed, offering the necessary stability to support the weight and functionality of the extraction system.

The second job was to design a similar extraction system at the plant located in Portugal. In this case, a reinforced concrete enclosure measuring 8 x 4 metres was designed with an adjustable suction hood at the top, which can be moved between two positions to allow the loading and handling of the material to be cut. The front enclosure was equipped with hinged panels to facilitate the entry of large parts and machinery.

The extraction system in Portugal was designed to operate in conjunction with the main suction duct of the electric arc furnace , ensuring that the scrap cutting process is synchronized with the main purification of the plant.

In the third assignment, we conducted a comprehensive audit of the plant’s smoke cleaning system, which had a number of recurring problems including poor ventilation, unreliable instrumentation signals, excessively high gas temperatures, and insufficient cooling in the quenching tower.

The audit was carried out in two phases:

Phase 1: Theoretical simulation. Simulations of the complete installation (primary and secondary suction) were carried out based on the data of the furnace metallurgy and the dimensions of the vessel. These simulations allowed obtaining a detailed view of the system performance in different phases of operation, highlighting the critical points to be improved.
Phase 2: Field Audit. This phase included monitoring and studying actual operating values, identifying specific areas where adjustments in design and operation were required to improve the efficiency of the treatment system.

Conclusion.

This comprehensive project to install, audit and optimise the smoke extraction and purification systems at this major steel plant has resulted in a significant improvement in the operational efficiency and safety of the scrap cutting and smoke handling processes.

The design of metal and reinforced concrete structures, combined with the optimization of fans and detailed monitoring of purification systems, has made it possible to reduce smoke emissions, improve system performance and ensure more efficient operation .

Integrating all work into a comprehensive approach has been key to ensuring that the systems not only meet the plant’s current needs, but are also prepared to meet future challenges, both in terms of performance and sustainability.

Whatever your needs, Hipatia Air Pollution provides you with the necessary resources.