Ferro Alloy Secondary Ventilation

M ikr oPul Pittsburgh Proposal 0262

- 11 August 5, 2011

MikroPul Pittsburgh proposes to supply a new Mikro

- Pulsaire  Pulse Jet system to treat

the e missions fro m Ferro Alloy tap hole , runner, ladle and casting bins venti lation process to be located in XXXXXX . The equipment and services proposed will be designed to meet the following parameters.

Gas Volume, Design: 15 0,000 ACFM Maximum Operating Gas Temperature: 275 ° F Normal Operating Gas Temperature: 200 ° F

Dust Loadi ng (average) Less than 1.0 grains / actual cubic feet

Outlet Lo ading requirement: Less than 0.0022 gr/dscf

Number of Modules: Six (6 )

Module Cloth Area: 8,456 square feet

Total Cloth Area: 50,736 square feet

Net Cloth Area: 42,280 square feet w ith Five ( 5 ) modules filtering

Gross Air : Cloth Ratio: 2.96 : 1

Net Air : Cloth Rat io: 3.55 : 1

Dust Fil tered: Metal fume Application: Submerged arc furnace tap hole, runner, ladle and casting bins Pulse cleaning mode: off or on

- line

Baghouse Equipment

Six (6 ) Model 323(6)

- 16

- 20 TRH Mikro

- Pulsaire  top removal walk

- in ple num dust

collector module in a 2 x 3 arrangement. Each module is furnished with the following:

Inlet Design: Patented Cascadair TM design distribution inlet device is proven to:

 Provid e extended bag life
 Lower pressure drop
 Reduce compressed air consumption
 Dispense air evenly
 Dramatically reduce maintenance and energyFerro Alloy Secondary

- Scope of Supply August 5, 2011 MikroPul Pittsburgh Proposal 0262

- 11 Page 2 of 9

 costs  Reduce dust retention on filters

Filter Bags: (1,938 ) 6.25 in. dia. x 16 ft. long 16 oz./(sq. yd.), Densi ty Polyester with PTFE finish on one side, triple sewn felt bags.

STYLE : POLYESTER FELT WITH

MEMBRANE

FIBER : POLYESTER

WEIGHT : NOMINAL 16.0 OPSY

SCRIM : FIBER SUPPORTED

PERMEABILITY : 7

- 12 CFM

MECH TREATMENT : PTFE MEMBRANE APPLIED

THICKNESS : 0.0550"

- 0.0850"

TENSILE : MINIMUM WARP 75 LBS

- FILL 150 LBS.

MULLEN : MINIMUM 375 PSI

SHRINKAGE : MAXIMUM 3 % FOR 2 HRS

AT 300 DEGREES F.

Retainers: Total 1,938 galvanized carbon steel, one piece construction retainers complete with integral venturi consisting of 12

vertical 1/8 in . dia. wires with horizontal rings spaced on 8 in. centers. All wires and horizontal rings are welded to the inside of the retainer, eliminating bag wear and premature filter failure. All retainers have been fully inspected to ensure there are no burrs, which can rub against the bags to cause leakage.

Assembly to be Snap Band type.

Housing: 3/16 inch carbon steel, welded construction furnished complete with design rating of ± 20 inches of water for dust tight service. The collector housing i s fully welded eliminating possible dust leakage.Ferro Alloy Secondary

- Scope of Supply August 5, 2011 MikroPul Pittsburgh Proposal 0262

- 11 Page 3 of 9

Hopper: 3/16 inch carbon steel, pyramid type with 60 degree side slope furnished complete with one (1) 24

- inch squared hinged and clamped access door. Hopper supplied with flanged discharge for 12

- inch va lve. Each hopper to have 3

- inch dia. p ipe nipple with threaded cap to rod out the hopper section above the discharge.

Clean Air Plenum: 3/16 inch steel, welded cons truction, walk

- in plenum type

, complete with one (1) hinged and clamped access door and one (1) exhaust connection.

Inlet Manifold: 3/16 inch carbon steel manifold to evenly distribute the dust

laden gas to each of the Six (6 ) modules. The manifold features bottom discharge (self

- cleaning) design. The

manifold will be stiffened for ± 20 inc hes of water.

Outlet Manifold: 3/16 inch carbon steel manifold to evenly collect the cl eaned gas from each of the Six (6 ) modules. The manifold will be

stiffened for ± 20 inches of water.

Tube Sheet Assembly: 3/16 inch carbon steel, bolted between plen um and housing flange, with openings for snap band bag and retainer assembly. Holes are on 8

- inch center spacing in both

directions.

Cleaning Assembly: The Mikro

- Pulsaire  has a rugged air distribution system that features thorough cleaning with no inte rnal moving parts and an automated self

- cleaning system that utilizes momentary jets of high

- pressure air through a specially designed venturi to provide efficient, thorough cleaning. Consisting of a carbon steel air supply header, brass

solenoid valves i n NEMA 4 enclosure, MikroPul right angle valves, aluminum construction, factory installed to the collector plenum section. Specially designed, stiffened blowpipes included.

Pulse Control: By local pulse timer, controlled by PLC, see below. Three

modes of pulse operation would be available, 1) o verall high

dP ; 2 ) t imed sequence and ; 3) m anual o verride. Individual module pressure drop will be monitored as well as overall baghouse pressure drop

.Ferro Alloy Secondary

- Scope of Supply August 5, 2011 MikroPul Pittsburgh Proposal 0262

- 11 Page 4 of 9

Electrical, Process Typical description Main PLC Control P anel consisting of the following:

Controls:

• 110vac power supplied to panel by customer

• NEMA 12 enclosure painted RAL 7035

• Siemens S7

- 315 PLC with 20% spare I/O

• Siemens TP177B, 5.7” color touch screen

• Siemens 1 pole circuit breaker for incoming 110vac

powe r

• Receptacle provided for laptop connection

• Terminals, wire duct, wire, etc.

, as required

Inlet Dampers: Each module is equipped with a fabricated 5 0

- inch dia., manually operated butterfly type damper. Open and C lose

limi t switch included for each damper . This damper to be used during maintenance

.

Outlet Dampers: Each module is equipped with a fabrica ted 5 0

- inch dia., air cylinder operated butterfly type damper. This damper is to be used for isolation during offline cleaning mode. Open

and C lose limit s witch included for each outlet damper

.

Module Supports: Structural support steel for local wind, seismic, equipment live and dead loads as applicable shall be provided. The

clearanc e under the fabric fil ter hopper flange shall be Six (6 ) feet. Hopp er loads for structural design are based upon the hoppers being 2/3 full by volume and with a bulk density

of 70 lbs./cubic foot.

Module Access Platform: A common service platform between rows of modules is located at the tubesheet level. The platform is constructed from steel bar grati ng with bar and angle type handrail and kick plate is included at each end of the walkway.

Stairs : One (1) 48” wide stairway from grade to the tube sheet level. 10” wide bar grating treads with checkered plate nosing, bar and rod handrail are also provided.

Ladder: One (1) caged ladder system will be provided from tube sheet level to grade.Ferro Alloy Secondary

- Scope of Supply August 5, 2011 MikroPul Pittsburgh Proposal 0262

- 11 Page 5 of 9

Rotary Valves: Six (6 ) 10 ” rotary valves, cast iron construction with vane wipers for connection to each pyramid hopper outlet fla nge. Each rotary valve is driven by a 1 HP gear motor.

Painting: All structural steel work and exterior surface of modules shall be primed and enamel finish painted (direct to metal) in the shop following an SSPC

- SP2 and/or SP3 surface preparation.

Instrumentation:

Module Timers Each module includes a clean on demand timer in a NEMA

4X enclosure.

Module DP Transmitter: Six (6 ) differential pressure transmitters are provided for remote indication of the module pressure loss as measured

acro ss the tube sheet The transmitter is a 0

- 2 0” W.C. range

with a 4

- 20 mA output signal.

System DP Transmitter: One (1 ) differential pressure transmitters are provided for remote indication of the baghouse pressure loss as measured from the inlet plenum to the outlet p lenum. The transmitter

is a 0

- 2 0” W.C. range with a 4

- 20 mA output signal.

Leak Detection System: The baghouse shall be equipped w ith Six (6 ) leak d etection probes to provide continuous monitoring of each module.

The output from the leak detection system sh all be sent to

the PLC.

Each probe will send a 4

- 20 mA signal.

Proximity Switches: Proximity switches (zero speed type) to be provided at each rotary air valve, Six (6 ) total.

Limit Switches: Open and C lose limit switches are include d for each module

inlet a nd outlet damper, Twelve (12 ) total.

Hopper Level Probes: Capacitance type level probes to be pr ovided for each hopper, Six (6 ) total. Model CLSI (or equal) detects theFerro Alloy Secondary

- Scope of Supply August 5, 2011 MikroPul Pittsburgh Proposal 0262

- 11 Page 6 of 9

presence or absen ce of material in contact with the probe by sensing a change in capacitance.

Thermocouples: One (1) thermocouple with transmitter is provided.

Manifold Pressure Regulators : Six (6 ) pressure sens o rs, one fo r each module

Compressed Air Pressure Transmitter: One (1) provided

Air Moving Equipme nt:

Air Moving Equipment and Accessories:

MikroPul will solicited fan quotations from various fan vendors and expects to negotiate with all of the bidders before award of a purchase order.

Main ID Fan: One (1) induced draft centrifugal, DWDI (double wi dth, double inlet), Arrangement 3, h eavy

- duty exhaust fan with

backward curve blades

.

The fan is selected to operate at 15 0,000 ACFM

at 200 °F and 18 inc hes of water.

Rated at 15 0,000 ACFM @ 18 ” and 200 ° F 1,2 00 RPM Electric variable position damper actuator (Beck) Anti friction bearings Bearing vibration and temperature ready Inlet and outlet flexible isolation joints Inlet boxes with louver dampers Gear coupling half mounted to fan shaft Drains with caps Split housing for wheel removal

Clips for insulation to be provided by installation contractor

Main Fan Bearing Each main fan bearing shall be equipped with a vibration

Vibration Sensors: sensor pick

- up. The output shall be for monitoring and alarm with shutdown on high set point.Ferro Alloy Secondary

- Scope of Supply August 5, 2011 MikroPul Pittsburgh Proposal 0262

- 11 Page 7 of 9

Main Fan Bearing Each main fan bearing shall be equipped with one (1) RTD Temperature Sensors: sensor with 4 to 20 milliamp output. The output shall be for high temperature alarm.

Main Fan Inlet Electric inlet damper actuators shall be provided capable of Damper Actuators: variable position continuous modulating control with 4 to 20 ma positioner. Linkage for mounting of the damper actuator at grade on a separate pedestal.

(Main Fan Motor): 900 HP 1200 RPM induction motor. The motor will be

rated for 4160V/3ph/ 60Hz TEAAC operation with a 1.15 service factor. Motors shall include stator RTDs, bearing vibration and temperature sensors, and space heaters.

Ductwork / Hoods / Stack & Installation

1. Unload, assemble and erect on concrete pads/pi ers fu rnished by others, Six (6 )

MikroPul Mode l 323(6)

- 16

- 20 TRH Mikro

- Pulsaire dust collectors including:

• One (1) lot of structural support steel

• Hoppers

• Clean Air inlet manifold

• Dirty Air Outlet Mainfold

• Tube sheet assemblies

• Walk

- in plenums

• Cleaning assembli es

• One (1) Rotary air lock valve for each hopper

• One ( 1 ) hopper slide gates for each hopper

• One (1) common access platform

• One (1) caged access ladder

• One (1) access stairway

• Siding girts

• Total of 1,292 filter bags and cages

2. Furnish and install all requi red piping and shutoff valves to connect Eramet supplied compressed air to the Four ( 4 ) cleaning systems.

3. Unload, assemble and anchor in place on concrete pads, o ne (1) 15 0,000 CFM fan.

4. Design, fabricate and install two (2) Hoods ( o ne approx. 8 ft. x 10 ft. over t ap hole and

o ne approx. 10 ft. x 20 ft. over l adle) and transition ductwork to form a 36 inch

diameter trunk

.

• Hoods to be fabricated out of 3/16” A

- 588 Corten or A

- 36 mild steelFerro Alloy Secondary

- Scope of Supply August 5, 2011 MikroPul Pittsburgh Proposal 0262

- 11 Page 8 of 9

• Transition piece Suitably stiffened for required static pressure using mild steel angle

• Flanged connections using mild steel angles

• Mild steel structural support towers

• expansion joint as required

• include positioning dampers in duct prior to each hood (30% to t ap hole and

70% to l adle

5. Design, fabricate and install 76 inch diameter ductwork from the transition piece to the

b aghouse, to the fan and from the fan to the stack.

• Duct will be fabricated out of 3/16” A

- 588 Corten or A

- 36 mild steel

• Suitably stiffened for required static pressure

• 76 in diameter or sized at app rox. 3,800 FPM

• Based on 200 ft straight run to Pulse Jet

• Flanged connections

• Mild steel structural support towers with saddles

• One (1) expansion joint fan inlet box

6. Design, fabricate and install one (1) 7’

- 0” diameter by approx 65 ’

- 0” tall stack

in cluding:

• Stack shell will be fabricated out 3/8” and 1⁄4” mild steel plate

• Stack base will be fabricated out of 1” mild steel plate with 1” upper support ring

• One (1) inlet breechings with stiffeners

• Two (2) 6” diameter test ports

• One (1) 180 degree access platform

• Caged access ladders with intermediate rest platforms up to 180 degree test port access platform

• Expansion joints from fan outlet to the stack inlet breeching

9. Leak test filter bags.

10. Precoat filter bags.

11. Start up assistance.

12. Structur al steel support towers, saddles and stack will receive one shop coat of

industrial enamel.

13. 4 inch mineral wool with aluminum cladding Insulation for main ID fan to reduce

noise levelsFerro Alloy Secondary

- Scope of Supply August 5, 2011 MikroPul Pittsburgh Proposal 0262

- 11 Page 9 of 9

Purchaser to Furnish

• Any required taxes.

• Means of cooling t he gas to a maximum of 275 ° F prior to the MikroPul interface.

• All duct work not mentioned above

• Fire protection or explosion suppression equipment if required

• Thermal or sound insulation if required.

• Electrical service for all MikroPul supplied equipment.

• Means of collecting dust from Rotary airlock outlet.

• Foundations.

• MCC.

• Lighting.

• All motor starters.

• All building permits and licenses.

• FAA approval for stack and stack aviation lights if required.

• Tax Exempt Certificate at time of order placement.

• Disposa l of all removed materials from the plant property if required.

• Stack sampling and testing if required.