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New Meltshop Air Pollution Control System

ton AC electric arc furnace
Office: Dallas 
Customer: Nucor Steel 
Location: Jewett, Texas, United States of America 
Timeframe: June 2002 – November 2002 
WorleyParsons completed the preliminary and basic engineering services for the off-gas system for Nucor Steel's new meltshop project to replace their existing aging meltshop.

The new meltshop consists of the following equipment:

  • 90 ton AC electric arc furnace (EAF)
  • Dual station ladle metallurgy furnace (LMF)
  • 5 strand caster

The primary objective of the project was to design the off-gas system using best available control technology to evacuate and clean the primary and secondary gases in order to maintain regulatory compliance. The selected off-gas system consisted of the following components:

  • Water-cooled 4th hole elbow
  • Water-cooled ductwork and drop-out box
  • Evaporative spray cooling system
  • EAF canopy hood and ductwork
  • Water-cooled LMF hood and LMF exhaust ductwork
  • Caster canopy hood
  • Two LMF booster fans and five primary baghouse ID fans
  • 1,600,000 ACFM positive pressure, reverse air-baghouse
  • Airslide dust conveying and dilute phase pneumatic conveying
  • Dust unloading facility

WorleyParsons utilized computational fluid dynamic modeling to optimize the size, shape, and exhaust rate of the EAF canopy hood in order to minimize overall operating costs of the fume collection system, while still maintaining greater than 95% fume capture inside the meltshop and zero emissions from the building.

In 2003, WorleyParsons Gas Cleaning was again contracted by Nucor Steel to provide Detail Engineering services to supplement services provided by other contractors. WorleyParsons scope for the Detail Engineering consisted of the following:

  • Process finalization
  • Instrumentation
  • Mechanical
The new meltshop began operation in 2004 with commissioning assistance provided by WorleyParsons Gas Cleaning.
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