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Zonguldak, Turkey

Ertem M.E.,Eregli Iron Steel Works Inc. | Sen S.,Dokuz Eylul University | Akar G.,Dokuz Eylul University | Pamukcu C.,Dokuz Eylul University | Gurgen S.,Dokuz Eylul University
Energy Sources, Part A: Recovery, Utilization and Environmental Effects

Eregli Iron and Steel Works Co. (Erdemir) is the largest integrated steel plant in Turkey. In this study, the potential for improving the specific energy use of slab furnace #3 of this plant was analyzed. An energy input and output model was established in order to determine the lost energy in the process. According to the study, energy efficiency of slab furnace #3 was calculated as 64.26%. Even though it seems to be a reasonable efficiency value for a slab furnace, it was noticed that further energy conservation can still be achieved by increasing the temperature of hot charging to the slab furnace and recovering the flue gas sensible heat remaining after the recuperator. Source

Ertem M.E.,Eregli Iron Steel Works Inc. | Sen S.,Dokuz Eylul University | Akar G.,Dokuz Eylul University | Pamukcu C.,Dokuz Eylul University | Gurgen S.,Dokuz Eylul University
Energy Sources, Part A: Recovery, Utilization and Environmental Effects

Specific energy consumption analysis of the integrated steel plants in Turkey was performed in this study by using the data of 2003-2005. Specific energy consumptions of three integrated steel plants were determined as follows: 30.3 GJ/TCS for Karabuk Iron Steel Works Co.; 29.8 GJ/TCS for Iskenderun Iron Steel Works Co.; and 21.5 GJ/TCS for Eregli Iron Steel Works Co. The results of the specific energy consumption analysis indicated that Eregli Iron Steel Works Co. (Erdemir) has the lowest specific energy consumption for steelmaking process in Turkey. The energy structure and management processes providing sustainability in Erdemir integrated steel plant was presented in detail. Source

Akkaya A.B.,Eregli Iron Steel Works Inc. | Copur H.,Technical University of Istanbul
International No-Dig 2015 Istanbul Conference and Exhibition

This study is about a waste water collection and treatment project to prevent pollution of sea water in Bosporus. The study includes 3 different microtunneling projects on which the same slurry type Herrenknecht AVN1800C microtunneling machine was used in Istanbul. Daily advance rates, net cutting rates, machine utilization ratios are investigated based on daily shift records, machine data logging records and visual in situ observations in different project sites. Lithological units and their properties are summarized based on the borehole reports and project documents. An empirical model is developed for predicting net cutting rate of the microtunneling machine. The dominant lithology is clay in all project sites investigated. Total driving length of the projects is 1000 m. The achieved best daily advance rate is 27.07 m/day. Average of the net cutting rates in all project sites is obtained as 1.96 m/h for these 3 projects. The highest average net excavation rate is achieved as 4.24 m/h in Kurbagalidere site and it varies between 1.1 m/h (Cirpici site) and 1.34 m/h (Nakkasdere site). Statistical analysis is performed to investigate the effects of some ground related parameters (natural water content, plastic limits, liquid limits, plasticity index, SPT-standard penetration values, and TCR-total core recovery) on net cutting rates. The best relationship is obtained with SPT values being lower than 15. Net cutting rate decreases with increasing SPT value. The model is valid for slurry microtunnel boring machines with 2.5 m of excavation diameter and clay-silt lithology with SPT values lower than 15. Source

Ertem M.E.,Eregli Iron Steel Works Inc.
Energy Sources, Part B: Economics, Planning and Policy

Eregli Iron and Steel Works Co. (Erdemir) began its activities on May 15, 1965 with an annual production capacity of 450.000 t and has made important contributions to Turkey's economy ever since. Today, with a total amount of crude steel production capacity exceeding 3.000.000 t, it is the largest iron and steel factory and the sole producer of flat steel in the country. Erdemir produces hot and cold rolled coils, zinc, tin, and chromium plated steel. Erdemir has attained the production potential of its entire power requirement amounting to 1.2 billion Kwh/y in the power plant. However, it continues to purchase electricity amounting to 15% of its total production capacity from the Turkish Electricity Authority national system in order to meet the fluctuating loads, which occur during the hot rolling process. The installed energy production capacity of Erdemir has reached 155 MW (195 MW in 2008) with two steam turbine generators, which were put into service in 1965 with a 10 MW capacity each; a steam turbine, which was put into service in 1978 with a 30 MW capacity; two gas turbine generators, each of which was put into service in 1997 with a 40 MW capacity; and a steam turbine generator/motor blower which was put into service in 2001 with a 25 MW capacity. The steam production capacity is 750 t/hr of which 600 t/hr is produced in five steam boilers and 160 t/hr is produced in two co-generation facilities. In this study, as the control volume, the limits of co-generation plant No. 1 in Erdemir have been chosen for a detailed energy balance analysis. By the identification of the energy sources that move in and out of the control volume, the energy output sources have been categorized as fractioned. For the implementation of the method, the balance study has been chosen. Thanks to this study, major energy losses have been determined. According to our calculations energy efficiency of the furnace was founded as 77,2%. It seems that Erdemir co-generation plant No. 1 has a highly energy-efficient production for sustainable energy generation. Erdemir co-generation plant has also been rewarded as the second most-efficient co-generation plant of Turkey by the Ministry of Energy in 2002. This study also aimed to show the importance of the energy balance of plants, in order to find energy losses from the process. The losses can be recovered to use primary energy sources effectively. Copyright © Taylor & Francis Group, LLC. Source

Derin B.,Technical University of Istanbul | Alan E.,Eregli Iron Steel Works Inc. | Suzuki M.,Osaka University | Tanaka T.,Osaka University
ISIJ International

In the present study, the impurity capacities (Ci) of phosphate, phosphide, nitride and carbide in binary and multi-component molten melt systems at different temperatures were estimated using the artificial neural network approach. The experimental data taken from the previous studies were introduced to the artificial neural network, then the calculated results were plotted against the experimental values for comparative purposes. Besides, iso-phosphate capacity contours on the liquid region of CaO-CaF2-Al2O3 ternary phase diagram at 1 773 K were generated and plotted by using the neural network model results. The calculated results obtained through neural network computation agreed well with the experimental ones and were found more accurate than those estimates based on some models. © 2016 ISIJ. Source

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