Oschatz GmbH Westendhof 10-12 45143 EssenGermany

Phone +49 201 1802-0Fax +49 201 1802-165www.oschatz.com

Plant engineering and waste heat systemsfor the iron and steel industry

Manufacturing plant in Kocaeli, Turkey

Oschatz has been producing boilers and wasteheat systems at its plant in Turkey for customersall around the world since 1997. In 2010, in aninitial expansion phase, a new plant was built inthe free trade zone in the Kocaeli region, roughly120 km south-east of Istanbul. As of 2011, plantsand components are being manufactured inaccordance with ASME standards, the PressureEquipment Directive, TRD/AD standards and ISO9001 in four new, modern workshops with a totalproduction area of 10,000 m2 (108,000 ft2) on the60,000 m2 (646,000 ft2) site. The superlative lo-cation, directly on the Sea of Marmara, providesideal logistic conditions. The production site inTurkey offers capacity for around 450 employees.

Production plant in Nanjing, China

To be able to supply the markets in Asia, Austra-lia and Oceania faster and more cost-effectively,Oschatz has built a second production plant inNanjing, China. Production at the plant began in October 2005. A second expansion phase atthis plant was completed only three years later in the summer of 2008. In seven bays with atotal floor space of 15,000 m2 (161,000 ft2),located on a 50,000 m2 (538,000 ft2) site withgood connections to the port of Changjiang,Oschatz now manufactures waste heat boilersand cooling stacks in accordance with theChinese GB, ASME, TRD/AD and ISO 9001 stan-dards. About 600 employees work here underEuropean management, in sales, engineering/design, in production, finance and procurement.

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To ease the burden on the environment andmake use of the thermal energy in waste gases,Oschatz has developed systems for cooling thehot, heavily dust-laden, carbon-containing waste

gases from iron and steel production plants.Oschatz designs, produces and installs com-plete converter waste gas cooling systemsfor oxygen steel works for international steelproducers. These systems, also called coolingstacks, convert the generated process heatinto steam that can be used for industrialpurposes. Oschatz also manufactures waste

heat boilers for installation downstreamof both sinter belts and sinter coolers and

for use in coking plants and coke dry quenchingplants. As usual with plants from Oschatz, eachconcept is based on the customer’s individualwishes and requirements. This is the only waythat these systems achieve the ultimate degreeof operational reliability and economic efficiencythat is expected of plants ”Made by Oschatz“throughout the world.

Oxygen steel plantsConverter waste gas cooling plants (coolingstacks) for waste gas from top and bottom blo-wing converters for full combustion and suppres-sed combustion with gas recovery.

Sinter plantsWaste heat boilers downstream of sinter beltsand sinter coolers with and without auxiliaryfiring and incorporating hot air recirculationfrom sinter coolers as combustion air for auxiliaryburners

Coking plantsWaste heat boilers in coking plants

Modernising plantsOver the last few years, Oschatz has specialisedin modernising existing steel works plants byrenewing the lower hood parts with optimal gascollection in order to meet the new environmen-tal protection requirements. Additional energyextraction is achieved, because the cleaned car-bon monoxide containing gas is not flared upas with previous systems, but can be dischargedcontinuously via a downstream accumulator.

Waste heat boiler downstream of sinter cooler at the Tata steelworks in IJmuiden, Netherlands

Oschatz is a plant constructor operatingworldwide. With more than 160 years of experi-ence behind it, the company now has about1,200 employees and has subsidiaries, represen-tative offices and branches around the globe. Ourplants for cooling waste gases and convertingrecovered heat into industrially utilisable steamare used throughout the world in the fields ofiron and steel metallurgy, non-ferrous metallurgyand chemical as well as power plant industry.

Iron and steel metallurgy has had a high prio-rity to Oschatz for many years. In order to relievethe environment and to recover the heat energyin waste gases, Oschatz develops problem solu-tions for cooling the hot, highly dust-loaded andcarbon monoxide containing waste gases fromproduction plants. Each plant concept is basedon customer and process-specific requirements,to ensure the highest degree of availability, ope-rational safety and profitability for the customers.Depending on their destination, the plants andcomponents are fabricated in the two extremelymodern production facilities in Kocaeli, Turkey,

and Nanjing, China. Naturally, we comply withall quality standards, such as ISO 9001, ASMEstandard, Pressure Equipment Directive, EU stan-dards etc. All Oschatz products are highly profita-ble, easy to maintain and offer easy accessibilityto the individual components.

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Our Market is the World

At home in the worldOschatz – best technology backed by experience

Profitable and environmentally friendly Waste heat systems for the iron and steel industry

The deflection bend of aconverter (BOF) coolingstack is installed at the TataSteel IJmuiden steel works.

Photo: Fix Media / www.fixmedia.nl

Obsolete methods and intensified competitionon the international stage are increasingly for-cing steel producers to introduce new, more pro-fitable production techniques. Plant componentsthat work flawlessly and reliably, and are spe-cifically designed to operate cost-effectively, formthe basis that paves the way for these trend-set-ting processes. Oschatz has the requisite know-how and can offer the technological solutionsto master the wide-ranging problems in the fieldof waste heat recovery, which is becoming evermore important.

Experience as the basis for new developmentsWhen it comes to designing the waste gas coo-ling systems to be built to meet its customers’individual requirements, Oschatz is able to drawupon many years of comprehensive experiencerelating to the planning and production of con-verter cooling stacks. Maximum efficiency inoptimisation of the steel production process isobtained in particular from the round designconceived by Oschatz, the advantages of whichinclude high levels of operational reliability andthe long service life of the components. Wastegas cooling sections designed according to thisprinciple have already been used in 2005 inconnection with the HIsmelt process, and arecurrently used in the HIsarna process.

Shaping the futureThe HIsarna process was developed as part of theULCOS (Ultra-Low Carbon Dioxide (CO2) Steel-making) project, the aim of which is to halve theemissions of carbon dioxide arising during steelproduction. In the HIsarna process the preheatingand partial pyrolysis of the coal in the reactor, themelting cyclone for melting iron ore and the mel-ting crucible for subsequent reduction of the ironore and iron extraction are all combined.

This process greatly reduces the consumption ofcoal, and consequently results in a significantcut in carbon dioxide emissions. The waste gasescontaining carbon monoxide that are produced inthe course of the HIsarna process are combustedin the waste gas cooling section specially develo-ped by Oschatz for this method, installed abovethe smelting reactor, and are cooled with the aidof water. The water is then cooled via a secondarycircuit before being fed back to the waste heatsystem. While the test plant is already deliveringvery good operational results and is meeting thestrict customer requirements perfectly, for com-mercial implementation of the HIsarna process itis envisaged that the waste heat will be utilisedin the form of economically and ecologicallysustainable evaporative cooling.

The advantages of the Oschatz-specificconstruction are:

■ Greater resistance to high gas-side overpressure

■ Reduced tendency towards accretions■ More uniform heat transfer■ More favourable flow conditions

Waste gas cooling plant for theHIsarna process in IJmuiden,Netherlands

Our Market is the World4 5

Pioneering TechnologiesPartner for innovation

Oschatz converter waste gas cooling plant with a liftable and

lowerable skirt down-stream of a basic oxygen furnace (BOF)

3D illustration of a converter cooling plant with piping

Utilize heatCooling plants for converter waste gases

The steam produced during the process is storedfor energy recovery in accumulators assuring acontinous steam flow to the works steam net-work. It can also be condensed or blown offunutilized. The operating pressure for evaporationcooling plants can be between 0.5 and 64 bar.The amount of saturated steam being producedcan be superheated externally if needed.

Comply with environmental requirementsAs authorities all over the world have issuedmore strict environmental requirements overthe last few years, Oschatz has been revampingolder steelworks more and more frequently. Tothis effect, particular emphasis is being placedon achieving optimal gas collection by renewingthe lower hood parts.

Oschatz designs and fabricates tailor-madewaste gas cooling plants worldwide. Customerscan select one out of the following two coolingprocesses:

■ Evaporation cooling■ Pressurized water cooling using nitrogen

pressure for high and low pressure in the closed circuit

Pressurized water plants are operated within apressure range of 10 to 32 bar and at tempera-tures between approx. 50 and 220°C in forcedcirculation.

The plants with evaporation cooling, operatein natural or forced circulation or in combinedoperation.

Even the best product can go wrong sometime; parts may need to be repaired or replaced.In such instances, our customers can rely on theexpert service provided by Oschatz. Our subsi-diary Oschatz Services and Solutions k.s. pullsout all the stops to keep downtimes at your plantto an absolute minimum. The speedy availabilityof spare parts, which can be installed on site byour specialists if required, helps us ensure thatyour plant can resume production as quickly aspossible. The components are built or repaired inthe OSS manufacturing facility in Zlíchov Praha.Total floor space: 850 m2 (7879 ft2).

What our service provides:■ The quickest possible plant availability

in the event of breakdown or repair■ Highly qualified repair personnel with

plant-specific know-how■ 24/7 emergency service

Consulting services from our team:■ Optimisation of operating costs■ Improved technical and personnel planning

of resources and costs■ Planning of environmental

protection measures■ Conversion of furnaces■ Performance-enhancing adjustment

of steam parameters

These skirts were installed at SSAB-Lulea, Swe-den in 1982 in the context of plant reconstructi-on for waste gas recovery with gas accumulation.

An Oschatz solution, which has since provenitself in numerous plants.The further development of this skirt was incor-porated at ThyssenKrupp Steel AG in Duisburg in2000 and is used without a sealing agent.

Sealing of the space between the skirt and thehood is effected using a double mechanical seal.This consists of copper sheets, which are screwedto a flange on the top of the skirt. Meanwhile,Oschatz has applied for a patent for the designof this skirt.

Our service team is ready to help you around the clock.

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Our Market is the World

Innovative and reliableDeveloped with the customers: Oschatz skirts

Oschatz Services & Solutions k.s.Expert support around the clock

Installation of a skirt with double mechanical sealing

Throughout the world, expert Oschatz employees are the key to obtaining the best-quality products.

Designing the lowest cooling hood componentto match the converter dimensions is crucial foroptimal collection of the primary gases comingfrom the converter. This applies in particular toair factors of 0.05 to 0.1. Oschatz has develo-ped and designed the necessary skirts in tubedesign in cooperation with well-known steel-works and gas cleaning companies.

Thus, since 1969, Oschatz has already beensupplying skirts in tube design with water sealto Thyssen AG in Duisburg, Somisa, Argentinaand Inland Steel, USA.

In 1973, skirts in tube design with ”externalring“, i.e. with a labyrinth seal, were installed forthe first time at SSAB-Lulea, Sweden.

Oschatz has developed a skirt for particularlytight spaces around the hood, for which neithera water seal nor an external ring can be used,using nitrogen or steam as a sealing agent.

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The OSS manufacturing facility in Zlíchov Praha ensures the speedy availability of spare parts.

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Oschatz GmbH Westendhof 10-12 45143 EssenGermany

Phone +49 201 1802-0Fax +49 201 1802-165www.oschatz.com

Manufacturing plant in Kocaeli, Turkey

Oschatz has been producing boilers and wasteheat systems at its plant in Turkey for customersall around the world since 1997. In 2010, in aninitial expansion phase, a new plant was built inthe free trade zone in the Kocaeli region, roughly120 km south-east of Istanbul. As of 2011, plantsand components are being manufactured inaccordance with ASME standards, the PressureEquipment Directive, TRD/AD standards and ISO9001 in four new, modern workshops with a totalproduction area of 10,000 m2 (108,000 ft2) on the60,000 m2 (646,000 ft2) site. The superlative lo-cation, directly on the Sea of Marmara, providesideal logistic conditions. The production site inTurkey offers capacity for around 450 employees.

Production plant in Nanjing, China

To be able to supply the markets in Asia, Austra-lia and Oceania faster and more cost-effectively,Oschatz has built a second production plant inNanjing, China. Production at the plant began in October 2005. A second expansion phase atthis plant was completed only three years later in the summer of 2008. In seven bays with atotal floor space of 15,000 m2 (161,000 ft2),located on a 50,000 m2 (538,000 ft2) site withgood connections to the port of Changjiang,Oschatz now manufactures waste heat boilersand cooling stacks in accordance with theChinese GB, ASME, TRD/AD and ISO 9001 stan-dards. About 600 employees work here underEuropean management, in sales, engineering/design, in production, finance and procurement.

Phot

o:Th

omas

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era