VISIBLE EMISSION SURVEY REPORT
CHAPARRAL STEEL COMPANY
MIDLOTHIAN, TEXAS
PEDCo ENVIRONMENTAL
-------
VISIBLE EMISSION SURVEY REPORT
CHAPARRAL STEEL COMPANY
MIDLOTHIAN, TEXAS
by
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-3546
Work Assignment No. 2
PN 3530-2
Task Manager
Mr. Dennis Holzschuh
U.S. ENVIRONMENTAL PROTECTION AGENCY
EMISSION MEASUREMENT BRANCH, MD-13
EMISSION STANDARDS AND ENGINEERING DIVISION
RESEARCH TRIANGLE PARK, NORTH CAROLINA 27711
August 1982
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VISIBLE EMISSIONS SUMMARY REPORT FOR
CHAPARRAL STEEL CORPORATION, MIDLOTHIAN, TEXAS
On August 23 and 24, 1982, a representative of PEDCo Envi-
ronmental performed visible emissions (VE) tests on the electric
arc furnace (EAF) melt shop. A representative from Midwest
Research Institute (MRI) recorded process data and melt shop
activity. The melt shop was evaluated during all phases of EAF
operation.
Two furnaces are located adjacent to one another in the melt
shop (Figure 1). The melt shop roof is closed over the furnaces
and open at both ends of the building. The emission control
system at this plant consists of separate capture systems for
each furnace. The capture systems duct emissions to a common
mixing chamber from which emissions are ducted to either of two
fabric filters. Primary emissions are captured by a direct shell
evacuation control system. Charging and tapping emissions are
captured by overhead canopy hoods. Above Furnace A there are two
canopy hoods, one for charging and the other for tapping emis-
sions. Furnace B has one large canopy hood. Fugitive emissions
that escape capture by the canopy hoods are captured in "sec-
ondary collection zones". These "secondary collection zones" are
created by sheet metal partitions on either side of the canopy
hood that extend down from the melt shop roof to the crane level.
-------
CROSS DRAFT »
PARTITION
MONOVENT
1 1
oo
FURNACE
RELINE AREA
O
SCRAP
BUCKET
ILD BAGHOUSE ^_
•12 «I3/S
» SECONDARY
COLIECTION
ZONE
SCAVENGER
DUCT
x fFW\N
i
ALLOY
BINS
MM
n
RNAC
i)
SECONDARY
" COLIECTION ZONE
CASTING AREA
*~ DUCT ~*
1
1
— ^ i
u.
SCAVENGER
DUCT
—f\
lF(
t
RNA
B
J
:E)
m — CROSS-DRAFT
PARTITION
>— ^— I LADLE
PREHEAT
STATION
1 — h
OO
FURNACE
RELINE AREA
O
SCRAP
BUCKET
NEH BAGHOUSE
| ^ ». 354 m'/t
MIXING
CHAMBER
TEST
LOCATION
Figure 1. Plan view - Chaparral Steel melt shop.
-------
Fugitive emissions trapped in these secondary collection zones
are evacuated by scavenger ducts. Furnace emissions are con-
trolled by two fabric filters.
Only Furnace B was operating during this testing program and
visible emission data were obtained concurrently with compliance
tests on the Furnace B system. The Furnace A pollution control
system was closed off by dampers prior to the mixing chamber
during testing. Process information obtained by the MRI observer
is included in Appendix C.
One hundred thirty eight 6-minute sets of visible emission
readings were recorded from the monovent located on the east roof
of the melt shop adjacent to Furnace B. The highest set averaged
3 percent opacity. Table 1 presents a summary of the six-minute
average opacities for this source. Figure 2 is a plot of the
average set opacities versus time.
Visible emission tests were conducted in accordance with EPA
Method 9 procedures by a certified observer. Readings were
recorded every 15 seconds for one hour. The observer then took a
break to prevent eye fatigue. During the break period, continued
surveillance was maintained on the monovent. Copies of the field
data sheets and observer's certification are included in Appen-
dices A and B.
-------
TEST NO. 1 8-23-82
% OPACITY
% OPACITY
OPACITY
o.u
4.0
3.0
2.0
1.0
0.0
11
i i i
-
• A. . . .
1 1
^••B 1 1 -J
i
00 1200 1300 1400 1500 1600 1700 1800
TIME
5.0
4.0
3.0
2.0
1.0
0.0
08
5.0
4.0
3.0
2.0
1.0
n n
TEST NO. 2 8-24-82
i i i
— . 1 1
-
. . f
i r i
f f
00 0900 1000 1100 1200 1300 1400 1500
TIME
TEST NO. 2 (CONTINUED)
i i i
i 1 4 :
1500
1600
1700
1800 1900
TIME
Figure 2. Summary of average set opacities versus time for the
B-furnace roof monitor.
-------
TABLE 1. SUMMARY OF SIX-MINUTE AVERAGE OPACITY
Test No: 1
Hours of observation: 1141-1801
Date: August 23, 1982 Source: B-Furnace Roof Monitor
Set No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Time
Start -
1141 -
1147 -
1153 -
1159 -
1205 -
1211 -
1217 -
1223 -
1229 -
1235 -
1247 -
1253 -
1259 -
1305 -
1311 -
1317 -
1323 -
1329 -
1335 -
1341 -
1353 -
1359 -
1405 -
1411 -
1417 -
1423 -
1429 -
1435 -
1441 -
1447 -
1459 -
1505 -
1511 -
End
1146
1152
1158
1204
1210
1216
1222
1228
1234
1240
1252
1258
1304
1310
1316
1322
1328
1334
1340
1346
1358
1404
1410
1416
1422
1428
1434
1440
1446
1452
1504
1510
1516
Opacity
Sum
15
40
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Average
1
2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
(continued)
-------
TABLE 1 (continued)
Test No: 1
Hours of observation: 1141-1801
Date: August 23, 1982 Source: B-Furnace Roof Monitor
Set No.
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
Time
Start -
1550 -
1556 -
1602 -
1608 -
1614 -
1620 -
1626 -
1632 -
1638 -
1644 -
1656 -
1702 -
1708 -
1714 -
1720 -
1726 -
1732 -
1738 -
1744 -
1750 -
1756 -
End
1555
1601
1607
1613
1619
1625
1631
1637
1643
1649
1701
1707
1713
1719
1725
1731
1737
1743
1749
1755
1801
Opacity
Sum
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
80
Average
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
Test No: 2
Hours of observation: 0855-1905
Date: August 24, 1982
1
2
3
4
5
6
7
8
9
10
11
12
13
0855 -
0901 -
0907 -
0913 -
0919 -
0925 -
0931 -
0937 -
0943 -
0949 -
0955 -
1001 -
1013 -
Source: B-Furnace Roof Monitor
0900
0906
0912
0918
0924
0930
0936
0942
0948
0954
1000
1006
1018
0
0
0
0
0
0
0
0
0
0
0
65
0
0
0
0
0
0
0
0
0
0
0
0
3
0
(continued)
-------
TABLE 1 (continued)
Test No: 2
Hours of observation: 0855-1905
Date: August 24, 1982 Source: B-Furnace Roof Monitor
Set No.
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
Time
Start -
1019 -
1025 -
1031 -
1037 -
1043 -
1049 -
1055 -
1101 -
1107 -
1119 -
1125 -
1131 -
1137 -
1143 -
1149 -
1155 -
1201 -
1207 -
1213 -
1225 -
1231 -
1328 -
1334 -
1340 -
1346 -
1352 -
1358 -
1404 -
1410 -
1416 -
1422 -
1428 -
1434 -
1500 -
1506 -
1512 -
1518 -
1524 -
1530 -
1536 -
End
1024
1030
1036
1042
1048
1054
1100
1106
1112
1124
1130
1136
1142
1148
1154
1200
1206
1212
1218
1230
1236
1333
1339
1345
1351
1357
1403
1409
1415
1421
1427
1433
1439
1505
1511
1517
1523
1529
1535
1541
Opacity
Sum
10
0
0
0
0
0
0
0
0
0
0
0
35
0
0
0
0
0
0
0
0
80
0
0
35
0
0
0
0
75
10
25
35
0
0
0
0
0
0
0
Average
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
3
0
0
1
0
0
0
0
3
0
1
1
0
0
0
0
0
0
0
(continued)
-------
TABLE 1 (continued)
Test No: 2
Hours of observation: 0855-1905
Date: August 24, 1982 Source: B-Furnace Roof Monitor
Set No.
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
Time
Start -
1542 -
1548 -
1554 -
1600 -
1606 -
1618 -
1624 -
1630 -
1636 -
1642 -
1648 -
1654 -
1700 -
1706 -
1712 -
1724 -
1730 -
1736 -
1742 -
1748 -
1754 -
1800 -
1806 -
1812 -
1818 -
1830 -
1836 -
1842 -
1848 -
1854 -
1900 -
End
1547
1553
1559
1605
1611
1623
1629
1635
1641
1647
1653
1659
1705
1711
1717
1729
1735
1741
1747
1753
1759
1805
1811
1817
1823
1835
1841
1847
1853
1859
1905
Opacity
Sum
0
0
0
0
50
0
0
0
0
0
0
0
0
0
0
0
0
0
15
75
0
0
0
0
0
0
0
0
0
0
0
Average
0
0
0
0
2
0
0
0
0
0
0
0
0
0
0
0
0
0
1
3
0
0
0
0
0
0
0
0
0
0
0
-------
APPENDIX A
FIELD DATA SHEETS
A-l
-------
A FURNACE SIDE
B FURNACE SIDE
EMISSION POINT
VAA/V
OLD BAGHOUSE
CHAPARRAL STEEL MELT SHOP - OBSERVER'S VIEW
-------
i
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COMPANY.
LOCATION
TEST NO.
DATE
TYPE FACILTY G-'t fC.t
r/ £.
CONTROL DEVICE
CLOCK TINE
OBSERVER LOCATION
Distinct to Discharge
Direction fro* Discharge
Height of Observation Point
BACKGROUND DESCRIPTION
HEATHER CONDITIONS
Ulnd Direction
Mind Speed
AMD lent Temperature
SKY CONDITIONS (clear, over-
.cast, I clouds, etc.)
PLUME DESCRIPTION
Color
Distance Visible
OTHER INFORMATION
RECORD OF VISUAL DETERMINATION OF OPACITY
HOURS OF OBSERVATION //•?/ -
OBSERVER 1>i<
PAGE/^_ OF *3
Initial
s&
f?,
I
OBSERVER CERTIFICATION DATE
OBSERVER AFFILIATION PCD^o' fnj'/
POINT OF EMISSIONS
HEIGHT OF DISCHARGE POINT J
Final
100
tb'
SUMMARY OF AVERAGE OPACITY
Set
Number
/£>
Time
Start-End
1141 — tl +(+
-•g//,
/Jos —,
OpactUy
Sum
Average
' '_"
Readings ranged from
to
opacity
The source was/was not In compliance with
at the time evaluation was made.
-------
RECORD OF VISUAL DETERMINATION OF OPACITY PAGE 18 OF /3
COMPANY
IO
NO
j ) G V
DATE
2—
TYPE FACILITY
OHITROL DEVICE
CLOCK TINE
OBSERVER LOCATION
Distance to Discharge
Direction fro* Discharge
Height of Observation Point
BACKGROUND DESCRIPTION
HEATHER CONDITIONS
Wind Direction
Hind Speed
Ant lent Temperature
SKY CONDITIONS (clear, over-
..cast. % clouds, etc.)
PLUME DESCRIPTION
Color
Distance Visible
OTHER INFORMATION
Initial
isso
Sfl/
4-
HOURS OF OBSERVATION
OBSERVER
/
— /&
OBSERVER CERTIFICATION DATE
OBSERVER AFFILIATION
POINT OF EMISSIONS ,
/9S
-------
RECORD OF VISUAL DETERMINATION OF OPACITY
PAGE
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COMPANY
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TEST NO.
DATE Xkfa.. •*
TYPE FACILITY
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CLOCK TIME
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at the time evaluation was nade.
-------
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RECORD OF VISUAL DETERMINATION OF OPACITY PAGE //OF
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LOCATION Ml&tft^"** ' r 75> y o^s
TEST NO. 7-
DATE /ta«* 24 j '' c' 72.
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CLOCK TIME
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-------
RECORD OF VISUAL DETERMINATION OF OPACITY
PAGE 16 OF /
HOURS OF OBSERVATION
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TEST NO. Z.
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RECORD OF VISUAL DETERMINATION OF OPACITY
PAGE (O_ OF
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LOCATION MiALt>t£i*A; 7>x» C
TEST NO. -*-
DATE A-t*t* •?. 4; & 7
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-------
RECORD OF VISUAL DETERMINATION OF OPACITY
PAGE 10 OF /7
COMPANY Cha.Da r-ra L iTiUx? L
LOCATION Mi J !<>>%;„»;. Texc^jS
TEST NO. ' ^ '
DATE >£^«, -2.4. fcr&> ft
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CLOCK TIME
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RECORD OF VISUAL DETERMINATION OF OPACITY PAGE /£ OF l°t
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-------
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COMPANY ;*;—>..-• or v-'/. <; f »•:.>./•/ rrx
TEST NO. .?. '
DATE /•«>•• C/ :' *. /?C'a^
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T&^C-fer/V^'.
A-24
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COMPANY _
LOCATION
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DATE /
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OBSERVATION RECORD
PAGE _g" OF _/j
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T<3 D 3/r> r A^ x-/
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A-27
-------
OBSERVATION RECORD
COMPANY C hn *c, uvy / Q£^ L> OBSERVER
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DATE
PAGE 2_ OF
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COMMENTS
AJ/r'r7 <5 &4-pr£r
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A-28
-------
COMPANY _
LOCATION
TEST NO.
DATE X?
OBSERVATION RECORD
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COMMENTS
3J ah* r
-------
COMPANY
LOCATION
TEST NO.
DATE
Trt
TYPE FACILITY &j A
POINT OF D11SS10NS #-/£
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Detached
COMMENTS
Eu/Z/iace ST/c /c
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A-31
-------
COMPANY
LOCATION
TEST NO.
DATE /L,
OBSERVATION RECORD
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COMMENTS
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A-32
-------
COMPANY
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TEST NO. £~
DATE /? .foc/5/" 24
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OBSERVATION RECORD
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COMMENTS
3& £ l*& ^ C
A-33
-------
COMPANY
/-
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DATE (\ur,
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TEST NO.
DATE K1
OBSERVATION RECORD
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AJti '•&$ £¥-' K
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A-35
-------
COMPANY
LOCATION ML
TEST NO. __
DATE tL'c,
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COMMENTS
t >7^ CA '* O ^»
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-------
COMPANY j
LOCATION
TEST NO.
DATE ft..
OBSERVATION RECORD
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COMMENTS
•sr^Ky v^ g«p
A-37
-------
COMPANY
LOCATION /£/
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DATE / .,-
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COMMENTS
A)rfre~>c.**tJ
-------
COMPANY
LOCATION
TEST NO.
DATE A<
OBSERVATION RECORD
... v& f & k-e/L. OBSERVER 7", C
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Attached
Detached
COMMENTS
A-39
-------
OBSERVATION RECORD
PAGE
COMPANY
LOCATION
TEST NO.
DATE *1t.**itS-f-
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45
O
o
o
o
o
o
o
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o
o
0
fi
0
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0
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STEAM PLUME
(check ff applicable)
Attached
Detached
COMMENTS
A-40
-------
APPENDIX B
OBSERVERS CERTIFICATION
B-l
-------
SOUTHWESTERN OHIO AIR POLLUTION CONTROL AGENCY
BOARD OF COMMISSIONERS MAIN OFFICE LABORATORY MICHAELJ.MALONEY
NORMAN A. MURDOCK 24°° B**™" «"*» 1675 G6S' *">* CHARLEsTsCHUMANN
ROBERT A. TAFT,, Cincinnati, Ohio 45214 Cincinnati, Ohio 45204 CHARIESE.SCHUMANN
ROBERT A. WOOD Phone: (513) 251-8777 Phone: (513) 251-8863
May 3, 1982
Mr. Tom Clark
PEDCO Environmental
11499 Chester Road
Cincinnati, OH 45246
Dear Tom:
On April 13 and 14, 1982, a "Smoke Emissions" field class for
the requalification of Air Pollution Control Officers was con-
ducted by the Southwestern Ohio Air Pollution Control Agency at
the Millcreek Barrier Dam located off Gest Street. The class
was conducted and test papers graded by Jim Sadelfeld, Supervisor
of Inspection.
The following personnel from PEDCO Environmental were qualified
at this session:
Thomas Clark Mark Phillips
Philip Schworer Daniel Fitzgerald
Dave Osterhart D. J. Loudin
Doug Orf Gopal Annamraju
A grade of 37 or under is passing.
The next session will be conducted on October 5 and 6, 1982, at
the same location. Personnel from your agency are welcome to attend.
Sincerely,
Charles E. Schumann,
Director
BYj/ Jim Sadelfeld,
Supervisor of Inspection
CES:JS:jcm
B-2
-------
APPENDIX C
PROCESS DESCRIPTION AND OPERATION SUPPLIED
BY MIDWEST RESEARCH INSTITUTE
C-l
-------
MIDWEST RESEARCH INSTITUTE
4505 Creedmoor Road
Raleigh, N.C. 27612
Telephone (919) 781 -5750
FINAL
Date: August 31, 1982
Subject: Site Visit—Chaparral Steel Corporation, Midlothian, Texas
Electric Arc Furnaces in the Steel Industry
EPA Contract 68-02-3059; ESED Project 79/9
MRI Project 4663-L
From: William V.
To: Dale A. Pahl
ESED/SDB/RDS (MD-13)
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
I. Purpose
The purpose of this trip was to monitor the operation of the new
ultra high power electric arc furnace (EAF) and the new negative-pressure
fabric filter by observing visible emissions from the melt shop roof.
II. Place and Date
Chaparral Steel Corporation
Post Office Box 1100
Midlothian, Texas 76065
Telephone: (214) 775-8241
August 23-24, 1982
III. Attendees
A. Chaparral Steel Corporation
Harry Borowczak, General Foreman—Melt Shop Maintenance
William Nicholson, Superintendent of Maintenance
B. Mullen Environmental Testing Company. Inc. (METCO)
Bill Mullen, Project Leader
C. Texas Air Control Board
Bill Chaffin
D. EPA, Reqion VI PEDCO ENVIRONMENTAL
Philip C. Schwindt By
C-2
Principal Laboratories 425 Volker Boulevard, Kansas City, Missouri 6411'
-------
E. Ferrco Engineering, Ltd.
Paul Complin
F. PEDCo Environmental. Inc. (PEDCo)
Thomas Clark
G. Midwest Research Institute (MRI)
William Terry
IV. Discussion
A. General
The Chaparral Steel melt shop contains two ultra high power EAF's;
Furnace A has a nominal furnace capacity of 104 megagrams (Mg) (115 tons),
and Furnace B has a nominal furnace capacity of 136 Mg (150 tons).
Furnace A is an existing furnace and Furnace B is a new furnace that was
added to the existing shop. Furnace B was commissioned on December 22, 1981
Table 1 provides some technical data about each of the furnaces. Furnace A
has an annual production capacity of 390,000 Mg (430,000 tons), while the
annual capacity of Furnace B is estimated at 544,300 Mg (600,000 tons).
Furnace B was the only furnace operating during the test period. Plant
personnel indicated that Furnace A would probably not be operated until
the end of 1982.
The steel produced in the electric arc furnaces is cast through one
of the two continuous casters that produce 12.7 x 17.8 centimeter (cm)
[5x7 inch (in.)] billets and 15.2 x 30.5 cm (6 x 12 in.) blooms. The
billets are made into concrete reinforcing bars or structural shapes
(rounds, flats, and channels.) The plant produces up to 35 percent
special bar quality steel. This plant employs 789 people.
B. Process
One charge and two back charges of scrap are routinely added to the
furnace. The scrap used at the facility is dirty and consists of various
grades including No. 1 bundles, No. 2 bundles (shredded auto scrap,
frames and rims), turnings, bushings, and some railroad tracks and wheels.
A typical makeup is 28 percent No. 1 heavy melting, 21 percent No. 2
heavy melting, 23 percent shredded auto scrap, 10 percent oily turnings,
10 percent revert, and 8 percent bundles. This composition will vary
based on the availability and cost of scrap. Lime is injected to the
furnace after each charge through a 4-in. hose. Oxy-fuel burners are
used to accelerate the scrap meltdown. Near the end of each heat the
molten steel is lanced with oxygen to reduce the carbon content of the
steel, coke is added to aid slag formation, and some of the slag formed
is poured off through the slag door onto the ground below the furnace.
Samples of the molten steel are taken and an analysis is performed to
determine what alloys should be added to the ladle to reach the desired
C-3
-------
TABLE 1. ELECTRIC ARC FURNACES TECHNICAL DATA—CHAPARRAL STEEL CORPORATION
Furnace A
Furnace B
o
A. Furnace parameters
~TNominal capacity
2. Shell diameter
3. Electrode diameter
4. Tapping temperature
5. Transformer rating
6. Heat time
B. Capture system
1. Design
2. Flow
Total
DEC system
Canopy hoods
Scavenger ducts
Slag pushing area
Control system—baghouse
1. Manufacturer
2. Type
3. Compartments
4. Total No. of bags
5. Bag dimensions
Diameter
Length
6. Air-to-cloth ratio
7. Cleaning
8. Fans
9. Pressure drop
10. Exhaust temperature
104 Mg (115 tons)
5.8 m (19 ft)
61 cm (24 inches)
1866°-1977°K (2900°-3100°F)
100 MVA
2 hours
Direct evacuation control,
canopy hoods, scavenger duct
system with partitions
136 Mg (150 tons)
6.7 m (22 ft)
61 cm (24 inches)
1866°-1977°K (2900°-3100°F)
100 MVA
1.5 hours
Direct evacuation control, canopy
hood, scavenger duct system with
partitions
212 m3/s (450,000 acfm) 354 m3/s (750,000 acfm) at 136°F
47 mVs (100,000 acfm) 52 mVs (110,000 acfm) at 650°F
165 ma/s (350,000 acfm) 260 m3/s (550,000 acfm) at 100°F
24 mVs (50,000 acfm) 24 mVs (50,000 acfm)
— 39 mVs (83,000 acfm) at 100°F -
American Air Filter
Positive-pressure
12
1,440 (polyester)
29.2 cm (11.5 in.)
9.5 m (31.0 ft)
3:1
Reverse air
Two scavenger fans
Two DEC fans
Three main fans
2.0-2.5 kPa (8-10 in.) water
60°C (140°F)
Wheelabrator Frye
Negative-pressure
24
6,120 (16 oz. polyester felt)
15.2 cm (6 in.)
4.3 m (14 ft)
5.5:1
Pulse jet
Two scavenger fans—20 hp each
Two DEC fans~300 hp each
Three main fans--l,400 hp each
1.75-2.0 kPa (7-8 in.) water
60°C (140°F)
-------
final product chemistry. Alloys that might be added to the ladle include
SiMn, C, FeMn, FeSi, Cr, and Ni.
Once the correct temperature has been reached, the molten steel is
tapped into a ladle held by an overhead crane. Alloy additions are made
to the ladle during the tap, which usually takes 4 to 5 minutes. After
the tap the remainder of the slag from the EAF is poured out on the
ground. The ladle is taken to the nitrogen stirring station where nitrogen
is blown through the molten steel to stir the steel to ensure uniform
temperature and chemical composition. When stirring is complete, material
to insulate the steel is added to the top of the molten bath and the
ladle is transferred to the casting area.
The slag that was poured out on the ground is pushed into the slag
pit by a bulldozer. This activity is called "pushing the pit" by the
plant personnel. The slag is loaded into a truck and taken to a site on
the steel mill property for reclamation. A private contractor, International
Mill Service, Inc. (IMS), reclaims steel from the slag for resale to
Chaparral Steel and sells the remaining slag material for use in road beds.
C. Air Pollution Control System
Process emissions from Furnace A and B, process emissions that are
evolved during melting and refining, are captured by separate direct
shell evacuation control (DEC) systems for each furnace. The fugitive
emissions, which evolved mainly during charging and tapping, are captured
by two canopy hoods located above Furnace A and one large canopy hood
above Furnace B. The canopy hoods and DEC systems for each furnace are
ducted separately to the control device mixing chamber.
On both sides of the canopy hoods for each furnace, sheet metal
partitions are suspended from the melt shop roof down to the crane level.
These partitions create secondary collection zones to capture emissions
that escape capture by the canopy hood. Each of these secondary collection
zones is evacuated with two scavenger duct systems that have individual
fans and are connected into the duct that exhausts the canopy hoods (see
Figure 1). The secondary collection zones also capture some of the
emissions generated by the ladle-stirring station and the continuous
casters.
The emissions from Furnace A and Furnace B are ducted separately to
a common mixing chamber. The mixing chamber acts as a buffer to reduce
the effects of rapid changes in the grain loading and temperatures of the
exhaust fumes associated with the different furnace operations. From the
mixing chamber, the emissions are ducted to one of two fabric filters.
Figure 2 is a flow diagram of the air pollution control system. The
fabric filter associated with Furnace A is a positive-pressure American
Air Filter (AAF) fabric filter with 12 compartments. The design flow
rate for this fabric filter is 212 actual cubic meters per second (m3/s)
[450,000 actual cubic feet per minute (acfm)]. The technical information
about this fabric filter is presented in Table 1.
C-5
-------
o
I
CROSS DRAFT .
PARTITION
NONOVENT
1 1
OO
FURNACE
RELINE AREA
0
\(.M
BUCKE
OLD BAGIIOUSE
2)2 ra3/s •*
. SECONDARY
COLLECTION ZONE
i
ALL
BIN
n
SCAVENGER
/DUCTs.
/ FANS \
«
(
DY
S
T~I
p
T
r T
RN/
A
V
|
1
3
SECONDARY
*"• COLLECTION ZONE~^
1
DEC
DUCT "
V
i
— ^ '
L
SCA\
/;
... ,5
h
r
•
r
IEH(
ICT
rl
RNA
B
_/
1ER
\
'R
SCRAP
BUCKET
i i
MIXING
CHAMBER
t AS I ING AREA
* — CROSS-DRAFT
PARTITION
LADLE
PREHEAT
STATION
1 1
OO
FURNACE
RELINE AREA
0
/
NEW BAGIIOUSE
_,„ 354 ro3/s
Figure 1. Plan view of Chaparral Steel meltshop.
-------
n
i
GUIUO1WE
DAMPER
DAMPER AC1UAIOR&:
D MOOUIAIING
O UOIOR Of-ERAIE3.
CB-AIN CTLIX-R
• MANUAL
-Or
A
I CONTROL
DAMPER
DIVER1IN6
GA1E
• WIRED IO PROGRAMMABLE
LOGIC CONIROLLER PLQ
A CAN K MAIIUAIIT
POSIIIONEO.
IPLC) LOC.IN MEUCs roiPil
ELECI. ROOM.
LS • LI HI SIVI1CH
AllO'A fUlllACE HS03
BlC-B HjRIUCE HOOD
A IOMC.<>»—•••-;_»;:;;«; [a
»| 'mam latin
rail AIR "FOLLUT.OM COUIROL
Figure 2. Air pollution control system for both furnaces—Chaparral Steel
-------
The fabric filter associated with Furnace B is a negative-pressure
Wheelabrator-Frye fabric filter that was designed with a flow rate of
354 m3/s (750,000 acfm). This fabric filter is considered a high ratio
fabric filter with an air-to-cloth ratio of 5.5:1. The bag cleaning
system is a pulse jet. The exhaust gases from this fabric filter are
vented out to the atmosphere through a steel stack. The dust collected
in the fabric filters is palletized and landfilled. Chaparral Steel has
plans to charge the pellets to the furnace in the future.
The melt shop roof is closed over the furnaces and open over the
furnace reline areas to maintain natural ventilation in the shop. During
the summer, the temperature in the shop can rise to 66°C (150°F) near the
shop roof. For this reason, the crane cab and electrical equipment are
air conditioned to avoid heat stress for the crane operator and heat
buildup in the crane electrical equipment. The heat from the furnace
operation would be a problem for the crane operator; however, the crane
cabs are air conditioned. The plant personnel indicated that there is a
potential problem with heat stress only when maintenance is being performed
on the crane.
C. Emission Testing
Chaparral Steel performed a compliance test of its new EAF (Furnace B)
on August 23 and 24, 1982. Only Furnace B and the negative-pressure
fabric filter were operating during the test. The main damper on the
duct from the Furnace A canopy hood was closed so that no air was drawn
into the mixing chamber (see Figure 2). Furthermore, a guillotine damper
between the mixing chamber and the old positive-pressure fabric filter
was closed so that no emissions were directed toward the positive-pressure
fabric filter. All the fans associated with the positive-pressure fabric
filter were shut off. The test included three Method 5 sampling tests,
two 2-hour carbon monoxide tests, three sulfur dioxide tests (for the
plant PSO permit), and opacity measurements of the baghouse stack and
shop monovent. The compliance testing was performed by METCO of Addison,
Texas. During the 2 days of the compliance test, Thomas Clark of PEDCo
read the opacity of visible emissions from the shop roof monitor on the
southeast side of the shop above Furnace B. On August 23, 1982, 5 hours
and 24 minutes of visible emissions observations were recorded and the
highest 6-minute average opacity was 3.3 percent. On August 24, 1982,
8 hours and 24 minutes of visible emission observations were recorded and
the highest 6-minute average opacity was 3.5 percent.
The furnace operated normally with only a few minor problems during
the test period. Table 2 contains a summary of the charge and tap times
for the heats covered during the tests. Appendix A contains the furnace
process information that was obtained by MRI during the test period.
Appendix B contains the Chaparral Steel 24-hour summary sheets and the
furnace log sheets. During heat No. 2185 on August 23, 1982, an electrode
broke off in the furnace. This broken electrode was retrieved from the
furnace and new electrode sections added. This delay took approximately
36 minutes, and visible emissions were not read during much of this time.
C-8
-------
TABLE 2. SUMMARY OF CHARGE AND TAP PERIODS FOR SOURCE TEST AT
CHAPARRAL STEEL CORPORATION
Time
Date Heat No.
08/23/82 2182
2183
2184
2185
2186
7 08/24/82 2195
2196
2197
2198
2199
2200
2201
Charge 1
„
1124-1125
1307-1308
1458-1459
1724-1725
(0806)
1001-1002
1138-1139
1308-1309
1432-1433
1604-1605
1746-1747
Charge 2
..
1143-1144
1336-1337
1558-1559
1754-1755
0849-0850
1028-1029
1157-1158
1328-1329
1451-1452
1634-1635
1805-1806
Charge 3
..
1218-1219
1402-1403
1615-1616
—
0905-0906
1045-1046
1217-1218
1344-1345
1507-1508
1652-1653
1827-1828
Tap
1113-1118
1257-1301
1445-1450
1702-1708
—
0951-0959
1130-1134
(1259-1304)
1422-1426
1554-1558
1737-1742
(1902-1906)
Heat length
97 minutes
103 minutes
130 minutes3
113 minutes
93 minutes
86 minutes
86 minutes
86 minutes
98 minutes
80 minutes
00
The delay during heat 2185 resulted when an electrode broke off in the furnace.
-------
furnace. During several furnace kicks, the dilution air damper on the
DEC system cooling chamber opened to allow air to cool the exhaust gas.
When the dilution air damper is open, the draft on the furnace through
the DEC system is greatly reduced and most of the emissions from the
furnace are vented to the overhead canopy hood.
V. Recommendations and Conclusions
The furnace and air pollution control system operated normally
during the visible emission source test with the exception of a few minor
furnace problems of short duration (including a broken electrode and
furnace kicks). The air pollution control system at Chaparral Steel is
very effective in the capture of furnace emissions. The DEC system
captures almost all of the melting and refining emissions except for
those emissions generated during oxygen blowing and during furnace kicks.
The fugitive emissions capture system also works well with the secondary
collection zone capturing most of the emissions that escape the canopy
hood.
The limited emissions that escape capture are vented out the shop
roof monovent and are of low opacity. During the source test, the highest
15-second interval opacity observed was 15 percent. This opacity was of
short duration and was partially caused by the ladle-stirring station,
which is not under the fugitive emission capture system. The highest
6-minute average for both days of testing was 3.5 percent.
The data gathered at this facility demonstrate that a well-designed
shop can reduce the release of fugitive emissions to well below the
existing NSPS level of 20 percent during charging and 40 percent during
tapping.
c-10
-------
Appendix A.
MRI Heat Logs for Chaparral Steel, August 23-24, 1982
Oil
-------
CHAPARRAL STEEL COMPANY
Page / of (g
TEST RUN
DATE:
HEAT NO. ,
GRADE (e>Q
FURNACE DESIGNATION
FIRST CHARGE WEIGHT
SECOND CHARGE WEIGHT
TIME:
START FINISH
//••'3 H'l*
7l^~ II M
8
. OOP
THIRD CHARGE WEIGHT
TOTAL WEIGHT
kWh USED:
COMMENT
OF?
II
45
47
//«7
//^S"
OFF -
^/a>/3u£M
CHEMICAL ANALYSIS: C Mn P S Si Ni Cr Mo Cu Al Sn
SPECS
1st SAMPLE
FINAL ^/ II
C-12
-------
CHAPARRAL STEEL COMPANY
TEST RUN
DATE:
Page Z of
HEAT NO. 2/Z3
GRADE
FURNACE DESIGNATION
FIRST CHARGE WEIGHT
SECOND CHARGE WEIGHT
TIME:
START FINISH
THIRD CHARGE WEIGHT
TOTAL WEIGHT
kWh USED:
COMMENT
oil fit
Deity -
QA/
72
/A/
Ofr/o^y
CHEMICAL ANALYSIS: C Mn P S Si Ni Cr Mo Cu Al Sn
SPECS ;
1st SAMPLE
FINAL __ _\
BAGHOUSE INFORMATION:
SOUTH FA*J-I£Q **/* £Asr r*NCoed-
C-13
-------
CHAPARRAL STEEL COMPANY
Page 3 of to
TEST RUN /_
DATE: £-33-
HEAT NO.
GRADE
FURNACE DESIGNATION
FIRST CHARGE WEIGHT
SECOND CHARGE WEIGHT
E
/2S,OOd
TIME:
START FINISH COMMENT
125,090
THIRD CHARGE WEIGHT //0 QVQ
TOTAL WEIGHT 3&O. O8Z>
kWh USED:
&LO*J
//(fro
73^2-
PIT
/+°*
To
off
CHEMICAL ANALYSIS:
SPECS
1st SAMPLE
FINAL
BAGHOUSE INFORMATION:
Mn
SI Ni Cr Mo Cu Al Sn
IQitJ. IfiluzT
F/W - /go
ffttJ-Tb AT* ft -
fftN
C-14
-------
CHAPARRAL STEEL COMPANY
Page ^ of G
TEST RUN /
DATE:
Matt* r**t -
10 /A/. .
C-15
-------
CHAPARRAL STEEL COMPANY
TEST RUN
DATE:
FURNACE DESIGNATION
FIRST CHARGE WEIGHT 125, OOP
SECOND CHARGE WEIGHT X2$
TIME:
START FINISH COMMENT
OF?
ON
OA/
Page ./""of
HEAT NO.
GRADE
THIRD CHARGE WEIGHT
TOTAL WEIGHT
kWh USED: 532.5
OF
To
C0CL&CTU/4
oc/r
/7/Q
CHEMICAL ANALYSIS: C Mn P S Si Ni Cr Mo Cu Al Sn
SPECS ; ^
1st SAMPLE
FINAL 4/5 74g Z/ 4-3 22^ *)'
-------
CHAPARRAL STEEL COMPANY
Page £ of 6?
TEST RUN / HEAT NO.
DATE: -5?~ GRADE
FURNACE DESIGNATION & THIRD CHARGE WEIGHT
FIRST CHARGE WEIGHT /X5"00a TOTAL WEIGHT b&Q
SECOND CHARGE WEIGHT /?&, OT> kWh USED:
TIME:
START FINISH COMMENT
To
/7^3 PM
/72-S
17
T*
77hz: U*AG- /AATZTCrtoAj .SV^TfeTK /f
CHEMICAL ANALYSIS: C Mn P S Si Ni Cr Mo Cu Al Sn
SPECS ;
1st SAMPLE
FINAL 2X1 fa 1b gj 237 /& \f\ 3+ 373 O /3
BAGHOUSE INFORMATION:
C-17
-------
CHAPARRAL STEEL COMPANY
TEST RUN
DATE:
FURNACE DESIGNATION
FIRST CHARGE WEIGHT
SECOND CHARGE WEIGHT
TIME:
START FINISH COMMENT
goo
27
Page _/_ of
HEAT NO.
GRADE
THIRD CHARGE WEIGHT //Q;
TOTAL WEIGHT 3fc>Q.
kWh USED: 4&Q,&
/A/
Dftrr>P&
CHEMICAL ANALYSIS: C Mn P S
SPECS
1st SAMPLE
FINAL 3ST L2S J2_ Ja
BAGHOUSE INFORMATION:
Si Ni Cr Mo Cu Al Sn
3o
C-18
-------
CHAPARRAL STEEL COMPANY
TEST RUN
DATE:
FURNACE DESIGNATION
FIRST CHARGE WEIGHT
SECOND CHARGE WEIGHT
TIME:
START FINISH COMMENT
9s?
Ml 7*06 &/
Page 2. of //
HEAT NO.
GRADE
THIRD CHARGE WEIGHT //Q
TOTAL WEIGHT
kWh USED:
IO
foe*J
CHEMICAL ANALYSIS: C Mn P S Si Ni Cr Mo Cu Al Sn
SPECS ;
1st SAMPLE
FINAL \
BAGHOU^E INFORMATION: '
C-19
-------
CHAPARRAL STEEL COMPANY
Page 3 of M
TEST RUN
DATE:
HEAT NO.
GRADE
FURNACE DESIGNATION
FIRST CHARGE WEIGHT <
SECOND CHARGE WEIGHT /25.00Q
TIME:
START FINISH COMMENT
10 & 10**
THIRD CHARGE WEIGHT II 0 '
TOTAL WEIGHT 3&Q pad
kWh USED:
104*
IIn
77^
77*3
II*
CHEMICAL ANALYSIS: ~C Mn P S ' Si Ni CrMo Cu AV Sn
SPECS ~
1st SAMPLE *
FINAL 3®
BAGHOUSE INFORMATION:
C-20
-------
CHAPARRAL STEEL COMPANY
TEST RUN
DATE:
8
FURNACE DESIGNATION
FIRST CHARGE WEIGHT /'25',000
SECOND CHARGE WEIGHT
TIME:
START FINISH COMMENT
//*>
opr
72 '?
PIT.
Verc
12
22
OiJ
7X1°
Page ff of //
HEAT NO.
GRADE
THIRD CHARGE WEIGHT /(p,
TOTAL WEIGHT
kWh USED:
CHEMICAL ANALYSIS: C Mn P S Si Ni Cr Mo Cu A1 Sn
SPECS \
1st SAMPLE
FINAL 3& US /? *+ ftp i&t _9i_ ^ 3ff _o /z_
BAGHOUSE INFORMATION:
C-21
-------
CHAPARRAL STEEL COMPANY
Page £~ of II
TEST RUN -2 HEAT NO.
DATE:
-------
CHAPARRAL STEEL COMPANY
Page
of
TEST RUN
DATE:
HEAT NO.
GRADE
FURNACE DESIGNATION
FIRST CHARGE WEIGHT
SECOND CHARGE WEIGHT
THIRD CHARGE WEIGHT /IP
TOTAL WEIGHT $&& \.aoO
kWh USED:
TIME:
START FINISH COMMENT
14*
A/'t
»/436
CHEMICAL ANALYSIS: C
SPECS _
1st SAMPLE _
FINAL
BAGHOUSE INFORMATION:
Mn P
S Si Ni Cr Mo Cu Al Sn
CfoP
T0*P
f %
C-23
-------
CHAPARRAL STEEL COMPANY
Page 7 of It
TEST RUN
DATE:
HEAT NO.
GRADE
FURNACE DESIGNATION C?
FIRST CHARGE WEIGHT /2^ OOP
SECOND CHARGE WEIGHT /2$"
TIME:
START FINISH COMMENT
THIRD CHARGE WEIGHT Ho
TOTAL WEIGHT &&O
kWh USED: 4*7.0
/Vg/
3^
A53'
CHEMICAL ANALYSIS: C
SPECS
1st SAMPLE
FINAL
BAGHOUSE INFORMATION:
-pec.
Mn
Si Ni Cr Mo Cu Al Sn
C-24
-------
CHAPARRAL STEEL COMPANY
Page _£_ of //
TEST RUN "2 _ HEAT NO.
DATE: fr'2
-------
CHAPARRAL STEEL COMPANY
Page Q TOTAL WEIGHT 3fo. 'poo
SECOND CHARGE WEIGHT / 2>S' 00 6 kWh USED:
TIME:
FINISH COMMENT
Poil&L OFF
o/J
OFP
7737 H^ TA? -
1*745
&r= MoiTCAJ
CHEMICAL ANALYSIS: C Mn P S Si Ni Cr Mo Cu Al Sn
SPECS ; ; ;
1st SAMPLE
FINAL /# #& 33 45 276 ^3 99 ^ sgf _£
BAGHOUSE INFORMATION:
n»
C-26
-------
CHAPARRAL STEEL COMPANY
Page lO of
TEST RUN ^ HEAT NO.
DATE: X'W-*^ GRADE A-
FURNACE DESIGNATION & THIRD CHARGE WEIGHT /(0 OQQ
FIRST CHARGE WEIGHT IZ&.ObO TOTAL WEIGHT
SECOND CHARGE WEIGHT I2S 6AO kWh USED:
TIME:
START FINISH COMMENT
n**
o/J
C/M &
l$>0(- PuStJ -SLA-6 tfif PtT
oPp
TTto^Q
OFF
CHEMICAL ANALYSIS: C Mn P S Si Ni Cr Mo Cu Al Sn
SPECS ;
1st SAMPLE
FINAL tn gVl _23_ 3T* 23B J9$_ 79 i£_ 336 O J±_
BAGHOUSE INFORMATION:
C-27
-------
CHAPARRAL STEEL COMPANY , .
Page // of //
TEST RUN % HEAT NO.
DATE: o ' 7- GRADE
FURNACE DESIGNATION O THIRD CHARGE WEIGHT tlQ.QOO
FIRST CHARGE WEIGHT A?£>,06Q TOTAL WEIGHT 3Gf .jOQ
SECOND CHARGE WEIGHT llS.QOto kWh USED:
TIME:
START FINISH COMMENT
&y Tfar
TIP
CHEMICAL ANALYSIS: C Mn P S Si Ni Cr Mo Cu Al Sn
SPECS \
1st SAMPLE
FINAL ,
BAGHOUSE INFORMATION:
C-23
-------
Appendix B.
Chaparral Steel 24-Hour Summary Sheets and Furnace Log Sheets
C-29
-------
O I--I A P A R R A I... <:> T I::! I-H I.
X* !:" U R N A O E:
x> A :i: i... Y T o M rs! A (3 in:
> -«* l"l R $:> U M M A R Y £2 25 — A U (3 —
*
;.i> o
TX>
n.
'HEftT '
NUMBER
5-2176
5-2177
5-2178
5-2179
5-2180
5-2181
5-?182
5-2183
5-2184
5-2185
5-2186
5-2187
5-2188
5-2189
HEAT
NUMBER
5-2176
5-2177
5-2178
5-2179
5-2180
5-2181
5-2182
5-2183
5-2184
5-2185
5-2186
5-2187
5-21E8
5-2189
AVG
HEAT
NUMBER
5-2176
5-2177
5-2178
5-2179
5-2180
5-2181
5-2182
5-2183
5-2134
5-2185
5-2186
5-2187
5-2188
5-2189
AVG
HEAT
NUMBER
5-2176
5-2177
GR. GR. GR. ORDERED CHEMISTRY
ST. FIN NAME
13 13 GR60 REBAR 14
13 13 GR60 REBAR *4
13 61 A-36 ROUNDS > 3/4
13 13 GR60 REBAR *4
0 0 NOT ASSIGNED
13 13 GR6D REBAR *4
13 13 GR60 REBAR *4
13 13 GR60 REBAR *4
13 13 GR60 REBAR *4
13 13 GR60 REBAR 14
13 13 GR60 REBAR *4
13 13 GR60 REBAR *4
13 13 GR60 REBAR *4
13 13 GR60 REBAR *4
TAP TO POWER TAP TAP- TAP-
POWER TIME TIME TAP CAST
12 2 129 139 25
16 145 307 138 1053
14 321 500 153 1900
12 512 629 129 36
640 640 755 755 32
31 826 938 143 40
15 953 1113 135 37
11 1124 1258 145 21
12 1310 1446 148 16
14 1500 1705 219 655
21 1726 1858 153 i?
16 1914 2042 144 22
11 2053 2216 134 19
10 2226 2351 135 37
42 210 300
CHARGE TAP HEIGHT PRIME
UEIGHT UEIGHT CAST HEIGHT
342000 282343 278983 278983
340000 281073 278273 275053
330000 278684 275156 246176
330080 311883 307963 278983
330000 305349 298629 298629
340000 286841 286841 286841
330000 3J152B 306488 306488
330000 314347 314347 314347
360000 290761 286841 286841
360000 282912 282912 282912
360000 294700 294700 294700
360000 302559 302559 302559
360000 306488 306488 306438
351000 318276 318276 318276
172.3 148.8 147.8 145.6
FURNACE DELAYS
MECH ELECT ELCTRD FETTLE
0 0 6 12
0 0 1 14
TAP
TEMP
3020
3040
3040
3040
3060
3850
2570
3040
3060
3050
START
CAST
154
1400
0
705
827
1018
USD
1319
1502
0
FINAL CHEMISTRY
c m p 's si cu
360 826 29 45 233 366
405 736 22 42 223 403
219 833 17 38 353 353
384 870 25 54 253 243
334 730 22 55 223 299
425 763 25 49 216 343
444 779 22 29 220 286
419 776 22 40 243 339
394 716 18 35 226 263
415 740 21 43 229 253
NI
129
146
139
126
136
133
113
129
129
99
283 810 26 31 239 373 153
430 743 22 38 226 406 150
410 876 34 30 256 386 136
394 766 27 51 236 403 146
END CAST LADLE TUNDISH REASON
CAST TIME TEMP FIRST LAST TERMINATED
331 137 2900 2800 2780 0 -
1621 221 3020 2320 2760 8 -
0 0 D 0 00-
850 145 2910 2810 2775 8 -
1018 151 2900 2790 2800 0 -
1150 132 2928 2810 2845 0 -
1319 129 2920 2820 2820 0 -
1502
1658
0
143 2920 2830 2815 0 -
148 2918 2885 2778 8 -
0 8 D 00-
3048 1935 2104 129 2930 2810 2840 0 -
3040 2104 2235 131 2920 2850 2820 8 -
3048 2235 28 153 2920 2820 2835 0 -
3060 28 200' 132 2900 2810 2800 D -
127 2505 2412 2404
RET'D P-BACK YIELDS
-------
c:: i-i A r-> A R R A i... ?•> T IH: i--:
x* r-" u R M A c:: IH:
X> A :il 1... Y T 0 N M A (3 IS!
HEAT ' GR. GR. GR. ORDERED CHEMISTRY
NUMBER ST, FIN NAME
5-2190 13 13 GR60 REBAR 14
5-2191 13 13 GR60 REBAR 44
5-2192 3 3 GR40 REBAR 45
5-2193 3 3 GR40 REBAR 45
5-2194 3 3 GR40 REBAR 45
5-2195
5-2196
5-2197
5-2198
5-2199
5-2200
5-2201
5-2202
5-2203
5-2204
HEAT
NUMBER
5-2190
5-2191
5-2192
5-2193
5-2194
1...
3 3 GR40 REBAR 45
3 3 GR48 REBAR *5
3 3 GR48 REBAR *5
3 3 GR40 REBAR 45
70 70 A-36 FLATS 1/4
70 70 A-36 FLATS 1/4
70 70 A-36 FLATS 1/4
70 70 A-36 FLATS i/4
70 78 A-36 FLATS 1/4
70 13 GR60 REBAR 44
TAP TO POWER TAP TAP- TAP-
POWER TIME TIME TAP CAST
11 2 122 131 38
17 139 258 136 32
9 307 457 159 11
14 511 629 132 34
15 644 806 137 24^
5-2195 17
S-2196 9
5-2197 11
5-2198 11
5-2199 12
5-2200 32
5-2201 10
5-2202, 14
5-2203
5-2204
AVG
HEAT
NUMBER
5-2190
5-2191
5-2192
5-2193
5-2194
5-2195
5-2196
5-2197
5-2198
5-2199
5-2200
5-2201
5-2202
£2263"
5-2204
AVG
15
9
13
CHARGE
HEIGHT
363000
360000
360000
360000
-3MMO
360000
360000
360000
360000
360000
360000
360000
330000
160000
342000
178.5
823 954 148 18
1003 1130 136 25
1141 1259 129 34
1310 1423 124 36
1435 1534 Hi 52
1606 1737 203 35
1747 1903 126 104
1917 2037 134 118
2052 2217 140 114
2226 2354 137 42
136 39
TAP HEIGHT PRIME
HEIGHT CAST HEIGHT
322205 322205 322205
346341 343653 333993
279683 278339 278339
329401 327721 327721
2B2828 28282? 282S23
291648 286048 282828
314253 314253 314253
341171 332211 332211
296296 296296 296296
345940 322420 274120
291853 290733 290733
323960 323960 323960
290733 290733 290733
320693 315653 315653
292852 286132 282912
155.7 153.8 151.6
TAP
TEMP
3040
3048
3030
3077
3050
3030
3030
3040
2990
3077
3090
3040
^3060
START
CAST
200
330
508
703
830
1012
1155
1333
1459
1626
1812
2007
2155,
£> ^ I--I R S:> U M M A R Y ;.
FINAL CHEMISTRY
C MN P 'S SI CU NI CR
415 850 24 39 243 . 313 163 99
415 826 25 45 250 323 156 ' 116
310 706 21 43 226 316 169 109
324 676 23 43 233 313 180 136
360 769 26 38 196 306 159 106
355 625 19 30 215 394
350 615 18 28 258 365
350 625 19 34 210 354
350 643 25'y 37 263 306
144 619 16 29 ISO 276
134 856 33 45 276 509
144 816 23 35 233 336
125 926 23 39 273 339
159
164
159
119
146
243
189
146
93 876 27 49 236 276 163
4151843 33 52 313 370 159
END CAST LADLE TUNDISH REASON
CAST TIME TEMP FIRST LAST TERMINATED
330 130 2900 2830 2820 8 -
500 130 2900 2800 2820 8 -
783 155 2928 2828 2828 8 - .
857 154 2920 2820 2810 8 -
1012 142 292(1 2941) PKfl fl -
1155 143 2910 2868 2325 8 -
1333 138 2900 2830 2300 B -
1459 126 2918 2820 2840 0 -
1626 127 2865 2788 2758 B -
1826 200 2990 2860 2800 8 -
2007 155 3000 2850 2840 8 -
2155 148 2988 2820 2820 8 -
2331' 136 2920 2825 2815 0 -
3060 2331 115 144 2950 2820 2320 6 -
3120 36 208 132 2920 2888 2826 8 -
141 2927 2825 2816
RET'D P-BACK YIELDS
-------
LYSIS_
iercd_
i
I Udlc
Of till
-c
iin
70
•p
Hfj Cr
Mo
Al
-;Cb
Code!
^^^^J^f
MATERIAL
Coke
Lime
Revert
1st
\Wtf
CHARGING BREAKDOWN
2nd
dV-eo"
Jcd.
nth
Totnl
Tfiffil, Fr.
T1ME
TAP
KWH
•Time
FeO
a.
Mn
4
Sil Cn
IH
Cr
Mo
Aim Tap Temp.
Jl Heavy
Aim Arr. Cast.
Ji! Heavy
Ladle Temp.
Shredded
4
Tap Temp.
Bundles
Freeboard
.1
Turnings
Bushing
GENERAL LOG-
v.Ht.Tapped^
KWH
.KHH/Ton
LADLE INFORMATION
Ladle No.
Pit Scrap
_Chn_._
or On
Re-Carb Tims
Aint.
Prev.llts.
Total
02 .On
Off
Cond. before
Power On
t
olil Mloyt
ClK|.
Cond. After
Power Off
Other
_Chg_._
~Cmj.
Total 0?
Temp.
KWH/Ton
otol HHllltci
er Off
07/Ton
. FCE REFRACTORY UFE
FURNACE ADDITIONS
Slag Thickness
LADLE ADDITIONS
Roof
llateial
Tine
Amount
Material
Amount
Eff.
,'t);»Rac'ex
Upper Section
SiMn
Coke
er Cn Time
To Tap l.v
Electrode VI
A , A
Middle Section
FeAl
SiMn
_;" 'i^owiEilrs
Bottom
u>
-N
:ode
AT
J?
/1~^
DELAYS
Start
Fin. Hr.
TEE
II
ja.
Reason
J.
Tap Fettle & Charge
6e£ereo^et • / j.
0, Probe
.43-
11
±2^
Material
iemarks:_ jl-
FURNACE PATCHING*!,
"1 * J ' -r- I
?.... /AZ.< /7
Amount
^3 ll.4(>
Location
-------
-------
lercd
Mn
-HEAT RECOUD
nun i nuriuuiv
|~s:T-sr
•CU'.
"Ni Cr
Mo
A1
••Cb
•" IfeXaa— 10KULK N0-' &'TK~
Code
Jlu"
IWERIAL
Coke
Liime -.
Revert
1st
CHARGING DREAKDOUN
2nd
Jed.
jlth_
Total
Infill.EC.
TIME
TAP
KWIj
;buh
. FeO C Mn
II. _£il J1L .£r_ "o|A1nl Tap Temp
GENERAL LOG-.
?v.Ht. Tapped KViH
-_Chg. ^T
Kc-Carb Time
Amt.
Jl Heavy
Aim Arr. Cast.
Heavy
Ladle Temp.
Tap
Shredded
L-L
Bundles
Freeboard
,—
LADLE INFORMATION
Turnings
Pushing
Ladle llo. 6-
, IPit Scrap
Prev.Hts.
Total
'or On 3,'OO
r.On..
Off
Cond.Before
Power On
To'.jl A'l'.O
Chg.
Cond.After
Power Off
Total 0?
Temp.
KWH/Ton
;er Off
0?/Ton
FCE REFRACTORY LIFE
FURNACE ADDITIONS
LADLE ADDITIONS
.Slag Thickness
Roof
Material
Tine
Amount ' Material Amount
Eff.
Upper Section
Silln
Coke
Electrode '-1
Middle Section
FeAl
SiHn
Bottom
I
-M-
CodC
Start
532
Fin.
31
i N
DELAYS
Mr.
Reason
Tap Fettle & Charge
t
ii^i
FoSi .--
3ZI
Material
FURNACE
Amount
Location,
Remarks:
-------
erod
'C
iin
V S j Si { Ctrj-Ni7 I Cr |Mo I AT ) V •'•Cb
{Code
MATERIAL
Coke
1st
CHARGING BREAKDOHN
2nd
Jlth
Totnl
Tnt.ll
TIME
'» Si
I l:Hle
if (ju
Lime -,
Revert
Time
FeO
Mn
Si I Cu
Cr HoIAim Tap Temp.
SI Heavy
Aim Arr. Cast.
#2 Heavy
Ladle
Shredded
Tap Temp.
Bundles
L£
Freeboard
.1
Turnings
Pushing
GENERAL LOG-.
v.Ht.Tapped KHH
.KKH/Ton
LADLE INFORMATION
Pit Scrap
Ladle Ho.
_Chn_._
or On
Ke-Carb Tims
Amt.
Prev.Hts.
-
Total
O2..0n
Off
Cond.Before
rr>
Pov/er On
Chg.
Cond.After
Pov;er Off
O'.hcr
Chg.
Total 0?
i emp.
KWH/Ton
OUl Kc'.illlCi
21- Off
Og/Ton
FCE REFRACTORY HFE
FURNACE ADDITIONS
LADLE ADDITIONS
Slag.Thickness
Roof
Material
Tine
Amount
Material
Amount
Eff.
St.
31
Rac'ex
Upper Section
SiMn
Coke
£00
er On Time
To Tap \>t
r\ rn:.r.
f
Electrode -1
Middle Section
FeAl
SiHn
Bottom
O COil'lEf.'TS
•~1 •- —
.ui ^
Ul
•V
v/vXtt
t> /A-:
^®
A;
szs
-23
7C
-ode
_FoS1 --
DELAYS
Start Fin
Mr.
Reason
Ta"p" Fett1e~&-€harge~
•fll
.12
09 Probe
111.
^^4^
Mater
FURNACE
iuniduMsiL
.Amount
lemarks:
Location
",'fr \
-------
,LY$IS
lorcd
1 U.-llf -
or cm
Time
' C
Temp.
lln
&L
FeO
•p 1 s^Fsi j -cu".
Mn
A
J)f_i_Cr | Mo |A1 I V
Si I Cu
rii
Cr
GENERAL LOG-
•v.Ht.Tapped
KfiH
jrb Tin
.KWK/Ton
Cb
Ilo
Aim Tap Temp.
Aim Arr. Cast.
Ladle Temp..
Tap Temp.
Freeboard
.1
Codel
LADLE INFORMATION
.adle No.
MATERIAL
Coke
Lime
Revert
Jl Heavy
«f2 Heavy
Shredded
Bundles
Turnings
Bushing
Pit Scrap
1st
CHARGING BREAKDOWN
Ci:
TUi
rf-
2nd
3_£L
JLtiL
IntisL
TIME
lf
TAP
RMH'
ioun
_£!)"__.
or On
Ro-Car Time
Amt. •
Prev.Hts. il
Total
0;;..0n
Off
Cond.Uefore
Power On
IQ-W
Chg.
Cond. After
Power Off
_Chg^
~~Cn
-------
^^!^l AL^^^^
\LYSIS
lercd
in
M
\ s-Jus-j_i^ar|-Nr_j_Cr_
Mo I AT
-Cb
Codel
7
CHARGING BREAKDOHd
i'lATEIUAL
Coke
Lime
Revert
1st
&00
$9-60*
2nd
^S"*J?T-I
I Time
Temp.
FeO
Si
Cu
li
Cr Jio
—i
Aim Tep Temp.
Jl Heavy
Aim Arr. Cast.
Heavy
Ladle Temp.
Shredded
. I
Tap Tenp.
Bundles
Freeboard
J/L-1'2.
GENERAL LCG-
:v.Ht.Tapped
: Chg.
-------
LYSIS
crcd
J( Cut
Mn
iiD
HL-AT KECOKU
HUM iiunuuiv
20
Hi" Cr
A
Cb
CodcT
[OKULK NO
MATERIAL
Coke
Lime
Revert
1st
CHARGING RREAKDOHN
JURHJ^J.
2nd
3rd
Ath
.Total
TIME
J&L
TAP
I-KHII
"oun
Time
Temp.
FeO
Mn
Cu
Mi
Cr
Ho
Aim
\£L
Heavy
Aim Arr.
Heavy
Ladle Temp.
Shredded
Tap Temp. #?&3 .KWK/Tori
Re-Carb Tims
Amt . :
LADLE INFORMATION
Pit Scrap
Ladle
Prev.Hts.Jt'
Total
1*
>..0n .
Off
Cond. Before
Pov;er On
Totll A1!or>
Chq.
Cond. After
Power Off
i
Other
Chg_._
Cntj.
Total 0?
Temp .
KWH/Ton
Og/Ton
WL
Toul I'clillUl
FCE REFRACTORY LIFE
FURNACE ADDITIONS
LADLE ADDITIONS
c>r Off
S1;-.g Thickness
Roof
Ma'feral
Tine
Amount
Material
Amount
Eff.
Rac'ex
Upper Section
SiMn
Coke
er Un T1me/fl7
To Tap
Electrode -1 ^-2 -^
...^OnrlEKTS
CO
V
V^
lode
Middle Section
FeAl
SiMn
Bottom
DELAYS
FcS1 -•
StartfFin. Hr.
M
Reason
Tap Fettle & Charge
\
j£
*
Z- .&*•
6 3
Material
FURNACE
Amount
*^^ /ft-
[pJJ]N£f!lc£E-J2i
lO
Location
Remarks:
-------
.YSlS
U)
Start
MV
Fin.
%4fc
Mr.
12-
Reason
lap Fettle & Charge
0,
Material
FURNACE PATCHING*!../?:
Amount
Location
Remarks:
-------
-------
LYSIS
ercd.
1 l:?|
...... .
— .
Hf
Si Cu
li
•
GENERAL LOG' . ' • •.-•..•
v.Ht. Tappet
Chn.
or On
Chg.
Chg.
Cng.
or Off
St. I'rf'Vin.
er On
Timei\in
To Tap fity
[ KViH 1
^
ft. KWK/Ton
Re-Carb Time
0^ -On
.Anit
i
. .
Off
Total
0? ,:
0?/Ton
' .
...i •
Sing Thickness '• ' ':.
Rac'ex .'. .
L Elect
rode '-1
fW-IENTS
^
i
' M
.
: • •
. ,
..... ..
Code
•-
«, ..
* I
A
s
*$
3"'S
Cr
f.r
Mo
no
Al V "Cb COdel AJot.
Aim Tap Temp.
Aim Arr. Cast.
Ladle Temp. 29 do
Tap Temp. jJfl^O
Freeboard
.1
LADLE INFORMATION fe-o Hfi
Ladle
Ho. 7 %
Prev.Hts. /J /V
Cond. before
Cond. After
Temp.
. FCE REFRACTORY LIFE
Roof
Upper
Section
Middle
Section
Bottom
DELAYS
Starl
K"? 1
f>M%
(-'«,
'•A
7
Fin.
It?
'
Reason
lap
Kettle & Charge
£*i *>
Tt
a
}
L
r
&*k^<$6df^'
MATERIAL
Coke
Lime •.
Revert
afl Heavy
9'i Heavy
Shredded
Bundles
Turnings
Bushing
Pit Scrap
Total
Power On
Power Off
KHH/Ton
CHARGING BREAKDOWN
1st
two
••
APt/W
Vy/
lo(y
l&l
2nd
yt/W
V<,i«*>
t>O7
(>£?
33-J.4
FURNACE ADDITIONS
Material
SiMn
FeAl
Time
0, Probe G^yM
*!** $ tf'b
»i*Ff i;a
nth
± —
I -
\
, ;
/
/
'i
t
';
£—
'
Totnl
Toll) Alloys
Other
oul Koullle
Tntfll Fr
LADLE ADDITIONS
Amount
100
ft"*- $L,
FURNACE
Amount
Material
Coke
SiMn
FcSi -
Amount
/CO
-j<3C3o
£?OO
«
TAP
KWH.
!ouni
,
.V
"' "
'+ )
-------
•i
LYSI.S ' C Mn "P
ered
;4 7-5
1 L:dle - .
*?*"1 /? f ? - 1
Time Temp. FeO C Mr
I/, 4-1
/o%
' "V"
s 1-STj-ar
p.
x >/
£0
30
S
fKf)
Si
GENERAL LOG'
ritAI KUCUKU
Hi' i Cr
•• ,
•
Cu
Ni
. -. •
v.Ht.Tapped]'-!)1) KbH <&
yv>U.o3
....... .
••
Mr.
/t|
0(*
0*-
• o\
" 'jA
'
'T
•r
• Reason
lap
Fettle & Charge
Mo tidf
foC/
-Ms
M
(Jbnfl^
,0M
I'.tf
i M*)
i^5i_
2nd
^00
/tfa,o
1\H7
30 A 9 '
FURNACE ADDITIONS
Material
SiMn
FeAl '
Tine
"
09 Probe 6l#< 5V 2
^/^.i T.i^
a.
Material
f$/4. /oa
i9ol% «vJlp
•
<3^ ^>J
rtll
nth
Tot.il
^J" °^
loul Allc/l
Other
!oi;1 ftotilllc
iTQj-Al F*1
LADLE ADDITIONS
Amount
/&
'Co
.tf- ;o*
FURNACE
Amount
^ou
Material
Coke
SIMn
FcSi •--
Amount
Jk>O
3 $00
$00
"/ fc'/il Cfi "?£>
*t..,tf;n
Location
Ol-'ftullo-. ft.. I. .
•• ^*
Eff.
~
URN ?t<£_ 8f-2^/-tft |
T IMC
1 Hit
M.
TAP 1KWI1'
.OUIl
:
— -•'
i
/.I • 1 *v \
------- |