From: Scott Gongaware

To: harris.jeff@ecrweb.com

Cc: Jim Elsesser ; Harvey Senger ; Eric Smith
Subject: MikroPul Baghouses - Ferro Alloy application

Date: Friday, August 05, 2011 10:54:06 AM

Attachments: 0262-11 EC R INC Reverse Air Primary.doc 0262 Scope Of Supply Pulse Jet secondary.doc

Jeff

I have attached Two (2) Scope of Supplies

1. Reverse Air Baghouse for Primary ventilation – 180,000 CFM

2. Pulse Jet Baghouse for Secondary Ventilation – 150,000 CFM

The Budget Price for Number 1 above is $6.1M

Budget Price for Number 2 above is 1.45M

Both are equipment only prices

I will be out till Aug 19 th – Please contact anyone of the distribution list for questions

Kind Regards

Scott Gongaware

VP Large Systems

MikroPul

724-934-3956Scope of Supply Typical Ferro Alloy Baghouse system Eight (8) Module Negative Pressure Suction Type Fabric Filter System MikroPul Pittsburgh Proposal No. November 4, 2008



### 1.0 Negative Pressure Reverse Air Cleaning Fabric Filter and Accessories

One (1) MikroPul Eight (8) Module Model 144

- 35

- 20 Negative Pressure Fabric Filter. Compartments are arranged in a double row configuration with a single plenum inlet and ducted outlet to a final stack discharge. The fabric filter will be designed and operat e, to meet the following conditions:

Inlet Gas Flow 180,000 ACFM Application Submerged Arc Furnace Melt Shop Gas Temperature for Fiberglass Filter Bags 500° F maximum continuous Gas Temperature for Design of Equipment 500 ° F maximum peak

Nor mal Operating Temperature 482° F Minimum Operating Temperature 70° F Inlet Dust Loading 0.77 grains/ACF Dust Bulk Density, Structural Design 70 lbs/ft 3
Dust Bulk Density, Power Calculations 70 lbs/ft 3
Dust Bulk Density, Volumetric Capacity 5 8 lbs/ft 3

Number of Modules Eight (8) Bags per Compartment 144 Bag Arrangement 12 wide x 12 deep Bag Reach from Cell Plate Walkways Three (3) maximum Bag Length 420 inches (35’

- 0”)

Module Cloth Area 14,891 ft2

Reverse Air Volume at 2.5:1 37,228 ACFM

Gross Air to Cloth Ratio @ 180,000 ACFM 1,50 :1 Net Air to Cloth Ratio @ 217,228 ACFM 2.08 :1
Net, Net Air to Cloth Ratio @ 217,228 ACFM 2.43 :1



### TYPICAL SCOPE DESCRIPTON BELOW

Modules:

The fabric filter will be constructed of modul ar design having no common walls between the housings. The design uses eight (8) modules that when installed on the support structure will have an air space between the modules with a minimum plate

- to

- plate spacing of 18 inches.Ferro Alloy Baghouse System

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Housing:

The module hou sing is to be stiffened 3/16” plate with design rating of ± 20 inches of water for dust tight service. External stiffeners are mild steel. The modules will be painted with a high temperature aluminum paint. The internal walkways and platforms

will be sho p installed.

Module Upper Housing Access Doors:

Three (3) access doors are provided for each compartment: The doors will be 24 inches wide by 60 inches tall with one (1) door located at the upper access level and two (2) doors located at cell plate leve l. The doors have high temperature gaskets.

Hoppers:

Hoppers are pyramidal type with a valley angle of 60 degrees. The hoppers are

fabricated from 3/16 inch thick A

- 36 steel plate. A 36” x 36” hinged, quick clamp access door is provided in each hoppe r. The door is a MikroPul design to provide proper sealing for a suction baghouse and allow for a basket stretcher to be handled through the opening. A confined space sign shall be mounted on each hopper access door. A special CascadairTM inlet gas dif fusion baffle is provided in each hopper. The hopper bottom opening is 12 inches x 12 inches. The hopper bottom flange is designed to accept a 12 inch discharge valve to mate with the pneumatic dust conveyor system.

Hopper flange clearance to be 4 ’

- 0 ” from flange to bottom of supplied steel column base plate.

Two (2), 12” x 12” pounding lugs will be provided on each hopper.

Cell Plates and Lower Internal Access:

Cell plates are fabricated from 3/16

- inch thick A

- 36 plate and have 12.0” diameter h oles

on 14

- inch centers in both directions. Two (2) walkways are provided at the cell plate level with nominal 24 inches of clear space between the filter bags. The maximum number of bags to be reached from any cell plate walkway is three (3) deep from the walkway. Access walks along the outside perimeter of the arrangement will be provided to access the module doors at cell the cell plate level. Walk ways are 30 inches wide.Ferro Alloy Baghouse System

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Bag Suspension and Upper Internal Access:

A full grating platform is p rovided at the bag suspension level inside the module. The grating is to be 1 1⁄4” x 3/16” type 19W4. The filter bags are suspended from bars welded to the grating via a chain and pin. A bag suspension spring is provided to maintain

tension on each filter bag. Compartment upper access doors are served by a 30 wide perimeter access walkway.

Structural Steel:

The internal structural steel stiffening frame and baghouse sub

- structure will be designed to meet local wind, snow and seismic loads. The support structure is based upon the hoppers of the fabric filter uniformly loaded with dust weighing 70 pounds per cubic foot with the accumulation taken as to the bottom of the hopper inlet ducts.

Stairway:

One (1) 30” wide stairway from grade to cell plate le vel and bag suspension level as shown in General Arrangement drawings. 10” wide bar grating treads with checkered plate nosing, bar and rod hand rail are also provided.

Ladders:

One (1) OSHA compliant emergency egress ladder system to be provided from all levels to grade as required by code.

Filter Bags and Suspension:

The filter bags are fiberglass with PTFE membrane (Mikrotex). The bag is rated at a maximum temperature of 550° F. Each bag weighs 10 oz./yd2 (nominal). The fabric

mullen burst is 500 PSI (minimum) and the permeability is 7 ±3 CFM at 1⁄2 inch w.g.

Weave pattern

– 3 x 1 twill.

Ring covers sewn with 2000 denier PTFE thread to meet warranty strength requirements.

Filter bags will be 12.0 inch diameter by 35’

- 0” long with 6.0 inch bo ttom cuff, 2.0 inch top cuff and eight (8) stainless steel anti

- collapse rings with 1.75 inch covers. The bags have a shop installed 20

- gauge galvanized cap with open eyebolt. The bottom snap

band is stainless steel with a double beaded bottom for cell plate attachment. 1% spares

is included.Ferro Alloy Baghouse System

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Bag suspension hardware is a double draw bar, spring assembly with chain and pin for fixing to bars on the upper level compartment grating floor. 18” spacing is provided between grating floor and bag top hook.

H oist:

A bridge crane with an electric hoist with sufficient capacity to lift all required maintenance materials to the service walkway is provided. The crane shall extend over one (1) end of the baghouse to provide clearance to lifting of materials.

Inl et Plenum :

The inlet plenum is located between the compartments at the cell plate level elevation and features a tapered top section and bottom exit design. The inlet damper valves are located in the duct stubs prior to the hopper inlet. The plenum is t o be fabricated from 3/16” thick sheet steel and stiffened for a negative pressure of 20 inches of water at 500° F. The plenum structural design is based upon the plenum being loaded with 70 pounds per cubic feet of dust at 25% volume. The plenum face c ro ss section yielding an inlet velocity of 3,500 f eet per minute

The plenum will have a minimum of two (2) 24” x 72” bolted opening access doors located in the plenum side walls.

Outlet Plenum:

The outlet plenum is located between the compartments at the bag housing elevation and features a tapered bottom section and top inlet design. The outlet and reverse air damper valves are located in the top section of the plenum. The plenum is to be fabricated from 3/16” thick plate steel and stiffened for a negat ive pressure of 20 inches of water at 500° F. The plenum structural design is based upon the plenum being loaded with dust at 70 pounds per cubic feet of dust at a uniform depth of six (6) inches. The plenum face cross

sec tion an outlet velocity of 2,640 fe et per minute with

Reverse Delivery Air Ductwork:

The reverse air duct is located above the modules and from the modules to the reverse air fan outlet at grade. It is designed to transport the reverse air from the grade mounted

reverse air fan to the compartment reverse air inlets then to the recirculation damper. It is to be fabricated from 3/16” thick steel plate and stiffened for a negative pressure of 30 inches of water at 500° F. The ductwork structural design is based upon the ductwork being l oaded with 70 pounds per cubic feet of dust at a depth of six (6) inches. The ductwork is 48 inch diameter with proper transitions to the fan outlet.Ferro Alloy Baghouse System

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Reverse Air Inlet Ductwork:

The reverse air inlet ductwork is 50 inches in diameter and runs from the outlet ductwork of the baghouse to the reverse air fan inlet at grade elevation. Proper transitions to the fan

inlet are included

. The ductwork is 3/16 inch stiffened plate construction for

- 20 inches

of water.

Inlet Dampers:

One (1) manual butterfly

- ty pe inlet damper shall be provided per compartment. 36 inches x 66 inches. These dampers are located in the inlet elbow to each compartment hopper. The damper actuators are mounted at the damper with chain fall to grade elevation.

Lock

- out provisions for Closed positions are provided.

Outlet Dampers:

One (1) outlet damper, multiple leaf poppet type with rolled angle seat shall be provided per compartment. The dampers are mounted above the outlet plenum. Each damper is

60 inch diameter. The shaft sha ll be stainless steel. Damper shaft seals are to be split gland type.

Outlet Damper Air Cylinders:

Each outlet damper will be provided with an air cylinder operator. The cylinders are Parker Model 2A with 10 inch bore and 60 inch stroke, solenoids and speed controls and Allen Bradley limit switches. Rod aligning couplers are included. Rods are chrome plated.

Reverse Air Dampers:

One (1) reverse air, multiple leaf, spring disc design, poppet

- type damper with rolled angle seat shall be provided per com partment. The damper is mounted on top of the module in the reverse air box. An access door in the damper housing shall be provided to access the seat and damper wafer.

Each damper is 50

- inch diameter. Damper shaft seals are stuffing box type.

Re verse Air Damper Air Cylinders:

Each reverse air damper will be provided with an air cylinder operator. The cylinders are Parker Model 2A cylinders with 10 inch bore and 40 inch stroke, solenoids and speed controls and Allen Bradley limit switches. Rod aligning couplers are included. Rods are chrome plated.Ferro Alloy Baghouse System

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Reverse Air Recirculation Damper:

One (1) reverse air, multiple leaf spring disc design, poppet

- type recirculation damper with rolled angle seat shall be provided for the baghouse. This damper pr ovides for recirculation of the reverse air preventing dead head operation of the reverse air fan. The damper is also used during the MikroPul soft re

- inflate sequence. The damper is mounted on top of the baghouse at outlet plenum elevation to tie the re verse air duct system to the baghouse outlet plenum. An access door in the damper housing shall be provided to access the seat and damper wafer. The damper is 40

- inch diameter. The damper shaft seal is stuffing box type seal.

The poppet blade is remov ed through a bolted panel on the housing.

Reverse Air Recirculation Damper Air Cylinder:

The reverse air recirculation damper will be provided with an air cylinder operator. The cylinders are Parker Model 2A with 8 inch bore and 32 inch stroke, solenoi ds and speed controls and Allen Bradley limit switches. Rod aligning couplers are included. Rods are chrome plated.

Reverse Air Fan By

- Pass Dampers:

Two (2) reverse air fan by

- pass dampers, butterfly type shall be provided for the baghouse to provide by

- pass of the reverse flow in the event of a reverse air fan failure.

One (1) damper is designated as the reverse air shut

- off damper while the other is designated as the reverse air by

- pass damper.

These dampers are in addition to the outlet guillotine d amper on the reverse air fan.

Reverse Air Fan By

- Pass Damper Air Cylinders:

The reverse fan by

- pass dampers will be provided with air cylinder operators. The cylinders are Parker Model 2A with stroke to suite arrangement, solenoids and speed

controls and Allen Bradley limit switches. Rod aligning couplers are included. Rods are chrome plated.

Main System By

- Pass Dampers: (design to include future 25% flow)

By

- Pass dampers NOT included, however provisions will be made to the duct to allow

installation o f by

- pass dampers at a later date

. Main System By

- Pass Damper Air Cylinder:

Not includedFerro Alloy Baghouse System

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### 2.0 Air Moving Equipment and Accessories

Base Main ID Fan:

Two provided

– One (1) operating and One (1) stand by, Class IV, double width double inlet, Arran gement 3, heavy

- duty exhaust fans with backward curve blades for continuous operation are provided. The fans are arranged for top vertical inlet and bottom angular up outlet.

T he fans are designed for 180,000 ACFM each at 482°F and 15.5 inches of water, based on a gas d ensity of 0.042 lbs./cu. ft Actual volume capacity in single fan operation will be confirmed following final system design and fan selection.

Backward Curved Type (single thickness Airfoil) Arr. #3, Class IV 1,180 RPM for Direct Drive Beck electric variable position damper actuator Bearing vibration and temperature included Inlet and outlet flexible isolation joints Inlet boxes with louver dampers Flex type coupling for variable speed application

2 1⁄2” drains Split housing for whee l removal Outlet guillotine damper with electric operator

Anti

- friction grease lubricated bearings

Final fan performance to be provided based upon certified

information and final duct S.P. confirmation.

450 Operating HP @ 16 ” WC, @ 180,000 ACFM and 482° F

I.D. Fan Hoist and Trolley Monorail:

A monorail beam for each I.D. fan will be furnished for the purpose of installing and removing the fan wheel and shaft from the fan housing.

The hoist, trolley and spreader beam required for each monora il will be supplied and installed by others.

Space is provided in the 480V MCC/PLC control panel for an electric hoist starter.

Main Fan Bearing Vibration Sensors:Ferro Alloy Baghouse System

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Each main fan bearing shall be equipped with a Vibration Pick

- up/Transmitter (4

- 20mA). The output shall be for monitoring and alarm with shutdown on high set point.

Main Fan Bearing Temperature Sensors:

Each main fan bearing shall be equipped with one (1) 100

- ohm platinum RTD sensor with 4 to 20 milliamp output. The output shall be for hig h temperature alarm.

Main Fan Inlet Damper Actuators:

“Beck” electric inlet damper actuators shall be provided capable of variable position continuous modulating control. Linkage for mounting of the damper actuator at grade on a separate pedestal. The Beck actuators include position feedback transmitters.

Main Fan Guillotine Isolation Dampers:

Two (2) fan outlet guillotine valves with electric motor drive are provided, one (1) for outlet isolation of each fan. The valves shall provide less than 1% leakage in the Closed position with 13 inches of differential pressure across the valve. Drive with electric motor and Open/Close limit switches is included.

Base Main Fan Motors:

Each main fan shall be equipped with a 600 HP; 1180

- RPM inverter type, mill duty motor. The motor will be rated for 2,300V/3Ph/60Hz operation with a 1.15 service factor. The temperature rise at the 1.15 service factor will be a Class F rise based on resistance. Motors shall include stator RTDs, bearing vibration, temperatu re sensors and space heaters. The motor has a WPII type motor enclosure.

All fan motors to have motor current protection to alter fan inlet damper position for

motor current control.

Reverse Air Fan:

One (1) reverse air fan SWSI for direct drive w ith Arrangement 3. Radial tip

construction.

Radial tip Blade Fan, Arr. #3, Class IV Rated at 40,000 ACFM (2.5:1 Reverse air ratio) 1180 RPM, 15.0” static pressure at 482° F

Single width, single inlet with inlet box air pre

- spin damper

Beck electr ic variable position damper actuatorFerro Alloy Baghouse System

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Anti

- friction bearings Bearing vibration and temperature drilled for instruments Inlet and outlet flexible isolation joints Falk gear coupling 1⁄2 mounted to fan shaft

2 1⁄2” drain Split housing for wheel removal

Gui llotine outlet damper with electric operator 128 Operating HP @ 16” WC, 4 0,000 ACFM and 482° F

Optional Spare Reverse Air Fan and Motor:

Not Included

Reverse Air Fan Bearing Vibration Sensors:

Each reverse air fan bearing shall be equipped with a Vibration Pick

- up/Transmitter (4

- 20mA). The output shall be for monitoring and alarm with shutdown on high set point.

Reverse Air Fan Bearing Temperature Sensors:

Each reverse air fan bearing shall be equipped with one (1) 100 ohm platinum RTD . The

ou tput shall be for high temperature alarm.

Reverse Air Fan Inlet Damper Actuator:

A Beck electric inlet damper actuator is included for control of the damper position. The Beck actuator is variable position type with position feedback transmitter.

Re verse Air Fan Motor:

One (1) 200 HP, TEFC, NEMA Design B, 1200 RPM motor 1.15 SF. Rated for 480 volts, 3 phase, 60 Hz operation. Motor to be supplied with bearing vibration pick

up/transmitters, bearing temperature RTDs and motor winding RTDs

– one (1) per phase.

The final motor HP selection is dependent upon the final reverse air fan selection and fan HP ratings.

Air Receiver (for Baghouse):Ferro Alloy Baghouse System

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300 gallon air receiver to be used for compressed air provided by others.



### 3.0 Dust Handling Equipment

Baghouse Hopper Dust Discharge Valves:

A gate type sized as required, nominal 6 inches is provided at the discharge of each hopper flange. The valve will include air cylinder actuator, solenoids and air speed control valves. Open/Close limit switches ar e also provided.

Spark Box Dust Discharge Valves:

A gate type sized as required, nominal 6 inches is provided at the discharge of the spark box. The valve will include air cylinder actuator, solenoids and air speed control valves. Open/Close limit swi tches are also provided.

Pneumatic Conveying System and Dust Handling System:

The pneumatic system will convey dust from the following pick up points:

Eight (8) baghouse module hoppers One (1) spark box hopper

The system is designed to operate at t he following capacities with the volume of 310,000

ACFM:

The anticipated dust load to the system is approximately 0.77 grain per actual cubic foot on average. Using 316,900 ACFM as a design volume and using a bulk density of 58 lbs. per cubic foot, the d ust load to the system would be 2,094 pounds per hour. The dust conveying system has been sized for 4,000 pounds per hour to provide extra capacity allowing recovery from maintenance down time.

Each baghouse hopper is capable of storing approximately 1,00 0 cubic feet of dust or approximately 58,000 lbs., storage level is taken as the bottom of the baghouse inlet. The level probes will be located below this elevation to provide adequate alarm notice.

The additional capacity of nearly 100% is to allow for “catch up” in the event of a mechanical failure of the conveying system.

In normal operation, the conveyor system will follow the cleaning cycle. When not in the cleaning cycle, the conveyor system will follow a cycle pattern to continuously removeFerro Alloy Baghouse System

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du st from the system hoppers. The system is controlled from conveyor line pressure and will continue to remove dust from a hopper until the system pressure indicates that the hopper is empty or the timer “override” steps to the next compartment.

An operat or may manually select a specific module to convey from or allow the system to simply operate automatically in normal mode.

Timer control settings and pressure settings are adjustable from the HMI.

Using a dust density of 58 lbs./cubic foot, the conveyi ng rate from a hopper would be 51.7 cubic feet per hour.

At the above system capacity the system would off

- load all of the 24 hours of dust storage to the silo in 25.2 hours in event of a complete system failure while with the net take away capacity of (4,000

– maximum inlet load) = 1,952 lbs. per hour net.

The following is provided:

• One (1) lot of six

- inch diameter conveying pipe with wear back, ceramic lined (or equal) elbows and discharge equipment.

• One (1) positive displacement blower with inlet fi lter, silencer, check valves, 75 HP,

480V/3Ph/60Hz 1800 RPM TEFC motor.

• The final blower motor HP selection is dependent upon final blower HP selection which may vary dependent on silo location and conveying distance.

• One (1) silo mounted receiver.

• One ( 1) silo mounted filter separator with double discharge valve, air cylinder, solenoids and speed control valves with Nomex bags.

• One (1) sound enclosure for 85 dBA sound level.

• Nine (9) hopper pick up points.

• Discharge ductwork to transport blower discharge to baghouse inlet.

• Broken bag detector.

• Filter separator.

Batching Silo:

A 12 foot diameter, 2500 cubic foot dust silo is provided for batch storage of the

collected dust. The silo is welded steel construction from mild steel 3/16” thick.

Perimeter roof access handrail is provided. The silo hopper is a 60° conical hopper with a 14 inch diameter discharge flange.

Silo includes roof mounted pressure/suction relief hatch and roof mounted Siemens or equal radar type dust level indicator.

Silo acc ess is via stairway from grade to hopper level platform and a spiral stairway is provided from hop p er level platform to silo roof.Ferro Alloy Baghouse System

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Support structure is arranged for approximately 23’

- 6” clearance under the silo hopper discharge flange, 70 lb/cf product weight, 20 PSF Deck Live Load.

Silo Coatings: Interior Epoxy = 2.0 mils AVG DFT per SSPC PA

- 2 Exterior Primer Epoxy = 2.0 mils AVG DFT per SSPC PA

- 2 Exterior Top Coat = Performance Urethane 1.5 mils AVG DFT Coatings are applied over an SSPC

- SP 6 and thermally cured.

Standard Color to be tan (special colors available at additional costs of $500.00)

Live Bottom:

Pulsonics, AR Fluidizing System located about the perimeter of the hopper.

Discharge Slide Gate:

14 inch diameter air operated slide g ate for isolation/maintenance of air lock and discharge spout.

Final Discharge Rotary Valve:

One (1) 14 inch diameter rotary airlock valve to be mounted directly beneath the slide gate. The valve is a cast iron construction and includes a gear reducer motor drive. A zero speed switch is included. The feed rate of this valve may be determined later.

Retractable Discharge Spout:

A retractable vented discharge spout mounted beneath the rotary airlock is provided. Spout it capable of positioning betwee n 5’

- 0” and 14’

- 0” as specified. The spout includes an electric motor drive and tilt probe for automatic retract. Limit switch interlock so door will not rise until the spout is lifted to be provided. A hand held pendant controller is

also included.

Dis charge Building:

A building with approximate dimensions of 18’ x 100’ x 18’ high will be provided with electric motor drive roll up doors on each end. A building ventilation system with blower and ductwork to provide one (1) air change every five (5) min utes based upon the empty building volume of 32,400 cubic feet yielding a ventilation rate of 6,480 cubic feet per minute. A blower rated at six (6) inches of water and 7,000 ACFM will be provided. A

close capture hood will be provided at the spout disc harge. The blower will be radial blade design with 15 HP drive at 1800 rpm. Fan will have a ducted inlet and motor willFerro Alloy Baghouse System

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MikroPul Pittsb urgh Proposal 0262 Page 13 of 27

be sized for start up with duct damper closed at 0°F and for continuous duty at 0°F. Vibration joints will be provided for the blowe r inlet and outlet. A 20

- inch diameter damper with air operated control and limit switches will be provided to isolate the fan from the main duct system during non

- operating periods and will provide damper closed start up. Limit switches are provided for position indication. Manually operated make

up air louvers are also included.

The fan discharge will be ducted to the baghouse inlet plenum.

NOTE: No scales or load cells are included in this proposal.



### 4.0 Spark Box:

One (1) spark box to drop o ut larger particles and sparks prior to the baghouse.

Maximum pressure drop through spark box to be less than 1.5” wg. vertical velocity

based upon 180,000 ACFM discharge side is 1,500 FPM.

The spark box is fabricated from 3/16 in. A36 mild steel and sti ffened for ±20 inches of water pressure and includes internal baffling.

Spark box hopper to have minimum 60 deg. valley angle and to be fabricated with 3/16 A36 mild steel and to be designed to be fully loaded with dust at 58 lbs./cubic foot. Hopper to have 36” x 36” access door. Two (2) poke holes to be included. Hopper to be equipped high dust level detector.

Spark Box Supports:

Structural support steel for local wind, seismic, equipment live and dead loads as applicable shall be provided. The c learance under the hopper is to match that of the baghouse hoppers for pneumatic conveyor layout.

Spark Box Inlet Isolation Joint:

A lined and insulated isolation joint is provided at the inlet to the spark box suitable for

the 550 o F.



### Water Spra y System:Ferro Alloy Baghouse System

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We have contacted TurboSonics who has supplied many H2O Two

- fluid type emergency cooling s ystems for many applications. After various meetings / discussions, Eramet has

decided to use a horizontal type system

Horizontal D uct as Cooler:

Spray nozzles and basic equipment as listed below mounted in the horizontal duct run. Access and required associated equipment included.

S YSTEM D ESCRIPTION

The SoniCool ® System proposed herein is a cooling system designed to provide gas cooling from an inlet t emperature to a discharge temperature set point by the injection of fine water sprays using a Turbotak dual phase nozzle. Sprays will evaporate to dryness

within the horizontal cooling chamber section, with dry particulate discharge and no free

water carr yover. The system is designed on the basis of data provided by the Purchaser as outlined in the proposal.

The main objective of #1 Furnace Gas Cleaning System Project is to provide a new baghouse system is to replace an existing wet scrubber emission con trol system in order to meet State and Federal EPA emission requirements in the off

- gas from #1

Furnace.

The SoniCool ® system will normally not operate, and is installed as an emergency spray system to handle unexpected temperature excursions in the pr ocess gas flow.

The final location and number of sprays as well as final process data to be

determined

E QUIPMENT S UPPLY D ESCRIPTION



###  No zzles are located in the furnace outlet duct location near the spark box

and are oriented around the duct perimeter



###  On e Inspection door at noz zle elevation



###  Ports for nozzle spray assemblies

P LATFORMS



###  Connecting walkways and platforms



###  At NozzlesFerro Alloy Baghouse System

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A TOMIZING N OZZLES



###  Nozzles and la nces as required



###  All nozzles and lances are interchangeabl e



###  All operating nozzles and l ances supplied



###  316SS, including mounting flange



###  Unibody Spray lance with Angled Lance tip as required



###  Turbotak air atomizing nozzles



###  Nozzle configuration:

 Welded construction, multiple orifice design.

 4” OD nozzle body

C ONTROLS



###  Automated controls for temper a ture setpoint control and response time



###  Controls may be supplied as separate assemblies or integrated on one assembly



###  Compressed air flow control

– (automatic setpoint)



###  Automatic air flow control valve, pneumatically

actuated based on 4

- 20 mA input signal for airflow setpoint control



###  Air flow and pressure indication with 4

- 20 mA

output



###  Inline air line strainer



###  Water flow control (automatic temperature setpoint):



###  Automatic water flow control valve, pneumatically actuated based on 4

- 20 mA input signal for t emperature setpoint control



###  Magnetic flowmeter water flow indication with 4

- 20 mA output signal



###  Local pressure indication as required



###  At Turbotak nozzles:



###  Quick connects and rubber flex hose connectionsFerro Alloy Baghouse System

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###  Diaphragm isolated pressure indication



###  isolating shu toff/adjusting hand valves for each

air and water connection



###  Air flow control with local flowmeter

Heat tracing, insulation or installation NOT INCLUDED

O NE (1) C OMMON W ATER P UMP S KID

One common pump skid to supply all water requirements

Two pumps install ed. One is operating, one is an online spare, to deliver the required water flow at required operating pressure to flow control valves. All components mounted on painted, mild steel frame, with all interconnected piping and electrical.



###  Centrifugal type pump, multistage



###  TEFC motor



###  Pressure Relief/recirculating valve



###  Pressure indication and pressure switch



###  All isolating valves, flow return, check valves as required



###  Inlet parallel, single basket strainers



###  Pressure indication and pressure switch

All isolat ing valves, flow return, check valves as required

“Preliminary Operating conditions below to be confirmed”

Operating Conditions

Number of Pumping
Stations 1

Capacity gpm 250

Head ft 280

Pump

Type Ansi Centrifugal

Manufacturer Goulds

Model 1 1/2 x 3

- 10

Performance

RPM 3600

Rated Eff. % 60

BHP / Installed Motor Rated HP (kW) 30 (25) / 40 (30)Ferro Alloy Baghouse System

– Scope of Supply August 5, 2011

MikroPul Pittsb urgh Proposal 0262 Page 17 of 27

W ATER S UPPLY T ANK

Heater with thermostat, not included

Quantity 1
Capacity gallons 1200
Style Carbon steel

Ventilation Flat bottom, flat top, round

Level Control 2” U

- vent

Water connections Modulating float control valve, level switch with

alarms.
Operating weight lb 11,000

O NE (1) A IR R ECEIVER

♦ One common air receiver

♦ Volume 8,000 gal

♦ Approximate size: 72 x 247 inch (approximate)

♦ C omplete with safety valve pressure gauge and automatic drain valve



### 5.0 Electrical Engineering and Equipment

PLC & SCADA Programming

Supply of control design and programming services including the following tasks:

• Functional Speci fication.

• Technical review meetings at Mikropul and at Site if required.

• PLC software programming with descriptors.

• SCADA (operator interface) software programming, fully tagged and annotated, with the following features as a minimum:

• Graphic overview of e ntire dust collection process, including system ductwork / dampers if applicable.

• Individual graphic displays of each module including details on all operating

parameters.

• Damper positions.

• Motor status of all motors and amperage of main ID Fans

• Compartmen t status.

• Compartment Cleaning Status.

• Graphic displays for the dust conveying system including details on all operating

parameters.

• Device pop

- up windows for all control devices.

• Baghouse Temperatures

.

• Baghouse system pressure drop

.Ferro Alloy Baghouse System

– Scope of Supply August 5, 2011

MikroPul Pittsb urgh Proposal 0262 Page 18 of 27

• Baghouse compartment pressure drop.

• Main ID Fan Damper position and motor amperage

.

• Bag leak detection system

.

• Hopper and Silo high level

.

• Real time and historical trending of all analog points, including temperatures, differential pressures and all temperatures and vibration points for exhaust fans

.

• Logging of above analog points to file.

• All alarms logged with time and date stamp.

• Hardware FAT (factory acceptance testing) at vendor s ystem’s facility.

• Software FAT (factory acceptance testing) at vendor system’s facility.

El ectrical Engineering for Contract (Equipment Supply Scope)

Supply of electrical engineering including the following tasks:

 P&I Diagrams.
 Electrical equipment list.
 Electrical equipment location diagrams.
 480 volt MCC

- Single line diagrams and schematic wiring diagrams.
 480 volt MCC

- Layout Diagrams
 480 volt Soft Starter

– Single line diagrams and schematics wiring diagrams.
 480 volt Soft Starter

– Layout Diagrams
 Ethernet and ControlNet RIO communications diagrams.
 RIO panels layout diagrams.
 PLC and R IO control panel terminal block layout diagrams.
 PLC and RIO control panel I/O Drawings.
 PLC and RIO control panel schematic drawings.
 PLC and RIO control panel backboard layouts.
 PLC and RIO control panel door layouts.
 PLC and RIO control panel bills of m aterial.
 Control Room Layout and Design
 Control Room Lighting and Electrical Services
 Specifying of dust collector instrumentation and control equipment.

PLC Control Panel

 1

- NEMA 12 Enclosure, approximately 60” high x 36” wide x 12” deep, with 12” hig h mounting feet.
 1

- Modicon Quantum PLC c/w Rack, Power Supply, all required I/O and

communications modules.
 1

- 1000VA Powerware or equal UPS
 1

- 120volt GFI receptacle for use by programmer.
 1

- 24vdc power supply, for Analog loop power.Ferro Alloy Baghouse System

– Scope of Supply August 5, 2011

MikroPul Pittsb urgh Proposal 0262 Page 19 of 27

 1

- Allen Brad ley 30mm, door mounted illuminated Control Power ‘On’ and

Control Power ‘OFF’ buttons.
 Lot

- Weidmuller terminals and fused terminals as required, all field items wire to

terminals
 UL Listed.

(2) HMI / Computer / SCADA S tations

Each station will consist of the following equipment and software, both stations will be placed in the electrical control room:

 Dell OptiPlex 755 (or equal)
 Intel Core 2 Duo Processor, E6550, 2.33GHZ.

 Windows  XP Professional SP2
 2GB DDR2 ram at 800MHz.
 Intel Graphics Media Accel erator GMA3000
 160GB IDE Hard Drive, 7200rpm.
 8x Slimline DVD

- CDRW Drive.
 19” Dell Ultra Sharp LCD flat panel monitor or equal.
 Dell Enhanced Keyboard.
 Dell Optical USB mouse.
 PC Anywhere for offsite support, or equivalent

 Integrated Intel  PRO 10/100 Ethe rnet  WonderWare by Intouch, Runtime license.
 1000VA PowerWare or equal UPS.

480V Distribution System

One (1) Square D, Service Line QED Switchboard 277/480 volt, 3 ph, 4

- wire solidly grounded neutral.

• 2

- Section NEMA 1 approximately 90” high x 72” wide x 36” deep.

• 42KA RMS symmetrical bus bracing.

• 3000 amp main circuit breaker, top entry.

• 3000 amp tin plated copper horizontal power bus.

• 2

– 800 amp circuit breaker feeders for 600 hp Stand

- a

- long VFDs.

• 1

– 800 amp circuit breaker feeder for the 480V MCC.

• 1 200 amp circuit breaker feeder ~ (1) 45k VA baghouse lighting transformer, (1) 200 amp baghouse lighting panel. Transformer and lighting panel supplied by others and mounted under baghouse.

• 2

– 60 amp circuit breaker feeders

– welding outlets.

• 1

– 30 amp circuit breaker feeder

– silo discharge local control panel.

• 1

– 30 amp circuit breaker feeder

– maintenance hoists.

• CSA Certified / UL Listed.Ferro Alloy Baghouse System

– Scope of Supply August 5, 2011

MikroPul Pittsb urgh Proposal 0262 Page 20 of 27

480V MCC

One (1) Allen Bradley, 480volt motor control center, 3ph, 3wire, solidly grounded neutral. Space saving NEMA Rated Starters, consisting of the following:

 5

- section, NEMA 1, gasketed, class 1, type B, approximately 90”high x 100”wide x 15”deep.
 42KA RMS symmetrical bus bracing.
 800 amp incoming line lugs

.  800 amp tin plated copper horizontal power bus

.  300 amp tin plated copper vertical bus.
 1/4” x 1” horizontal ground bus.
 1

- 60amp Fused Feeder and (1) 25kVA Control Transformer, and (1) 42cct Lighting Panel for 120vac control power with 42

– 15amp, single pole breakers

.  1

- FVNR 15hp starter

- Discha rge Building Blower.
 2

- FVR 10hp starters

- Main ID Fan guillotine dampers.
 1

- FVNR 200hp starter

- Reverse Air Fan.
 1

- FVNR 75hp starter

- Conveying System Blower
 2

– FVNR 30hp s tarters

– Pumps for Nozzles.
 Lot

– (minimum 1) empty section for future l oads.
 All listed FVNR and FVR starters are complete with, Fused disconnects, control transformer c/w primary and secondary fusing. Motor fuses’ are Gould AJT.
 UL Listed

.

Silo Discharge System Local Operators Panel:

• NEMA 4 enclosure approximately 30" hi gh x 24" wide x 8" deep, wall mounted.

• 480/3/60vac door interlocked rotary style non

- fused disconnect.

• 1

- Allen Bradley NEMA Rated, FVR starter for 1 1⁄2 hp silo rotary valve

• 1

– Allen Bradley NEMA rated FVR starter for 1 1⁄2 hp discharge spout

• 1

- Control tr ansformer c/w primary and secondary fusing.

• Allen Bradley, 30mm door mounted operators.

• 1

- Rotary valve “start” push button.

• 1

- Rotary valve “stop” push button.

• 1

- Rotary valve “running” pilot light.

• 1

– Discharge spout “up” push button.

• 1

– Discharge s pout “down” push button.

• 1

– Discharge spout “up” pilot light.

• 1

– Discharge spout “down” pilot light.

• UL Listed.Ferro Alloy Baghouse System

– Scope of Supply August 5, 2011

MikroPul Pittsb urgh Proposal 0262 Page 21 of 27

Local Motor Operators:

• Each m otor (6 in total) will have a local mounted operator station, consisting of the following:

o ‘Local

- Remote’ Selector Switch

o ‘Start’ Button

o ‘Stop’ Button

o ‘Emergency Stop’ Button

(8) Compartment Remote I/O Panels:

• NEMA 4 painted steel panels, approximately 30” high x 24” wide x 8” deep, wall

mounted.

• 200watt panel heater with integral thermostat and blower.

• 1

- Modicon Remote interface units.

• Lot

- Modicon Remote I/O modules as required.

• 1

- Sola/Heavy duty surge protector.

• 1

- Selector switch for Compartment ‘Auto

- Isolate’

• All I/O points will be wired terminals.

• UL Listed.

(2) ID Fan Remote I/O Panels:

• NEMA 4 p ainted steel panels, approximately 30” high x 24” wide x 8” deep, wall.

• 200watt panel heater with integral thermostat and blower.

• 1

- Modicon Remote interface units.

• Lot

- Modicon Remote I/O modules as required.

• 1

- Sola/Heavy duty surge protector.

• All I/ O points will be wired terminals.

• UL Listed.

(1) Reverse Air Fan Remote I/O Panel:

• NEMA 4 painted steel panels, approximately 30” high x 24” wide x 8” deep, wall.

• 200watt panel heater with integral thermostat and blower.

• 1

- Modicon Remote interface units

.

• Lot

- Modicon Remote I/O modules as required.

• 1

- Sola/Heavy duty surge protector.

• All I/O points will be wired terminals.

• UL Listed.Ferro Alloy Baghouse System

– Scope of Supply August 5, 2011

MikroPul Pittsb urgh Proposal 0262 Page 22 of 27

(1) Dust Conveying System Remote I/O Panel:

• NEMA 4 painted steel panel, approximately 30” high x 24” wide x 8” deep

.

• 200watt panel heater with integral thermostat and blower.

• 1

- Modicon Remote interface units.

• Lot

- Modicon Remote I/O modules as required.

• 1

- Sola/Heavy duty surge protector.

• All I/O points will be wired terminals.

• UL Listed.

(1) Baghouse System Remot e I/O Panel:

• NEMA 4 painted steel panel, approximately 30” high x 24” wide x 8” deep.

• 200watt panel heater with integral thermostat and blower.

• 1

- Modicon Remote interface units.

• Lot

- Modicon Remote I/O modules as required.

• 1

- Sola/Heavy duty surge pro tector.

• All I/O points will be wired terminals.

• UL Listed.

OPTION

– 480 V Soft Starters:

Two (2) 480 volt Soft Starter Panels, each consisting of the following:

• NEMA 12 rated ventilated enclosure, approximately 90” high x 42” wide x 20” deep , free stand ing.

• 1

– Main incoming fusible disconnect 480/3/60 Hz.

• 1

– Control transformer c/w primary and secondary fusing as required by code.

• 1

– 600 hp 780 amp Allen

- Bradley SMC Flex controller for ID fan, 1.15 service

factor.

• 1

– Fan ‘Local

- Off

- Auto’ selector swi tch.

• 1

– Fan ‘Start’ push button.

• 1

– Fan ‘Running’ pilot light.

• 1

– Fan ‘Speed’ pot switch.

• 1

– VFD ‘Fault’ pilot light.

• UL Listed.

OPTION

- Shop Assembled Control Room

One (1) approximately 1 0 ’ x 2 4 ’ pre

- assembled building, as manufactured by Provinci al Partitions or equal, consisting of the following:

 Steel base (floor) with 1⁄4” steel checker plate, epoxy painted.Ferro Alloy Baghouse System

– Scope of Supply August 5, 2011

MikroPul Pittsb urgh Proposal 0262 Page 23 of 27

 Pre

- Finished walls:
 Exterior walls

- 29 gauge pre

- finished metal siding
 Interior walls

- vinyl clad gypsum panels
 Insulation:
 Wall

- R12 c omplete with poly vapor barrier
 Ceiling

- R20 complete with poly vapor barrier
 Floor

- R20 complete with poly vapor barrier

- spray foam.
 Rooms:
 High Voltage Room

- to contain 480V MCC and (2) 480V soft starters.
 Operators Room / Storage Area

- room for de sk (supplied by others) and for storage of Baghouse maintenance items.
 Wall and roof structure to consist of metal framing members
 Roof covering to consist of single ply EPDM membrane
 Ceiling to consist of vinyl clad panels.
 Doors and Frames:
 (2) Exterior doors, door frames complete with pre

- finished metal slab door, hinges, seals, sweeps, lockset and closers, (1) 3’ x 7’ main door, (1) 6’ x 8’ double

door.
 Electrical includes:
 Exterior HPS light c/w photo cell
 Exterior ground fault receptacles.
 Lot

- inter ior lighting as required.
 Lot

- interior receptacles as required.
 Lot

- Installation of 480 V V FDs, 480V MCC and PLC control panel, complete will all internal wiring between VFDs, 480V MCC and PLC panel, completely tested prior to shipment.
 HVAC System as required

Instrument List:

- Four (4) Rosemont Temperature thermocouple with transmitters

- Ten (10) Rosemont pressure transmitters

- Eight (8) Hopper level detectors, capacitance typ e level probe with 20” insertion length

- Sixteen (16) Baghouse Inlet damper limit switches

- Sixteen (16) Baghouse Outlet damper limit switches

- Sixteen (16) Baghouse Reverse air damper limit switches

- Two (2) Baghouse Recirculation damper limit switches

- Eight (8) main system by

- pass damper limit switches

- Four (4) main ID fan inlet damper Limit switches

- Four (4) main ID fan outlet guillotine valves limit switches

- Two (2) reverse air fan damper limit switches

- Four (4) Main air fan bearing vibration detectors

- Four (4) Main air fan bearing Temperature detectorsFerro Alloy Baghouse System

– Scope of Supply August 5, 2011

MikroPul Pittsb urgh Proposal 0262 Page 24 of 27

- Two (2) Reverse air fan bearing vibration detectors

- Two (2) Reverse air fan bearing Temperature detectors

- Two (2) limit switches for silo discharge retract spout

- Eight (8) bag leak detectors with transmitter s

- Two (2) Main Fan inlet damper actuators

- Two (2) Main Fan outlet guillotine valve actuators

- One (1) Reverse air Fan inlet damper actuators

- Thirty

- two (32) Baghouse system ductwork damper actuators

- One (1) Silo radar level detector

Motor List : (Final M otor Sizes TBD)

- Two (2 ) 600 HP, 2400 V/3PH/60 Hz for main ID Fans

- One (1 ) approx 200 HP, 480 V/3PH/60 Hz for reverse air fan motor

- Two (2) 10 HP, 480V/3PH/ 0 Hz, Main Fan Guillotine damper motors

- Reversing

- One (1) 1.5 HP, 480V/3Ph/60 Hz, Silo disch arge Rotary valve motor

- Reversing

- One (1) 75 HP, 480V/3Ph/60Hz, Positive displacement blower motor

.

Note: Electrical quantities of limit switches, transmitters etc will be adjusted to include requirement for spray tower and pelletizer



### 6.0 Ductwor k

MikroPul will provide A36 mild steel ductwork as follows and as generally shown on the general arrangement drawings:

• Beginning at the existing off

- gas duct flange at the building east wall to the inlet of the spark box. (if selecting horizontal spray c ooler)

• Beginning at the existing off

- gas duct flange at the building east wall to the inlet of the vertical chamber, out of the vertical chamber and into the sparkbox. (if selecting vertical spray cooler)

• From the outlet of the spark box to the inlet of th e Baghouse inlet plenum.

• From the outlet of the Baghouse outlet plenum to the inlet of the Fan inlet

manifold.

• From the outlet of the fan outlet manifold to the stack.

• From the dust discharge building to the baghouse inlet duct for building

ventilatio n.

Included in all ductwork will be required expansion joints, inspection doors, support steel, saddles and trusses as required.

Support steel of dirty side duct to be designed based on 33% full of dust.Ferro Alloy Baghouse System

– Scope of Supply August 5, 2011

MikroPul Pittsb urgh Proposal 0262 Page 25 of 27

All Ductwork will be constructed of minimum 3 /16” A36 mild steel. The ductwork will be shipped in full diameter sections and lengths as allow by trucking limits. This will speed up installation.

The inlet and outlet of each main fan and the reverse air fan will have isolation joints to

reduce vibra tions being transmitted from the fans to the ductwork.

Main Stack:

A 10’

- 6”diameter by approx. 93 foot tall outlet stack will be provided for final system discharge. The stack will be constructed of minimum 3/16 inch A36 mild steel plate at

the disch arge with thickness at the base a minimum of 1⁄4” thick plate dependent upon final stack design. A 360° access platform will be provided that test port elevation with caged ladder system to grade.

Two (2) 4” IPS test ports with caps will be furnished at 90° orientation for stack testing.

Access to the interior of the fan outlet manifold will be by means of two (2) 24” x 72” quick opening access doors located on either side of the manifold.



### 7.0 Painting:

All exterior surfaces of the baghouse and all relat ed cladding, ductwork, silos, and other items supplied shall be painted a color of gray, to be matched by the Vendor to a color sample that will be provided by the Owner. No paint used shall contain lead.

Inlet manifold, modules and dust hoppers shall b e shop painted on the exterior with an approved heat resistant aluminum paint capable of withstanding 550°F and be 3.0 mils minimum dry film thickness. No internal surfaces are painted.

Exposed Structural Steel : All exposed structural steel shall be clea ned in accordance with Structural Steel Painting Council (SSPC) Specification SP

- 6. All surfaces will be sprayed with one (1) coat of red oxide primer, not to exceed 3 mils dry film thickness. After complete drying, all surfaces will then be painted with a finish coat of ICI Devoe

Devran 224HS paint. Thickness of top coat not to exceed 1.5 mils DFT. Total dry paint film thickness to be 4.5 mils or less. Final or top coat to be readily available grey color mutually agreed upon by MikroPul and Eramet.

Internal Structural Steel: Structural steel that is not exposed to the elements or is protected by dust building siding will be cleaned in accordance with SSPC SP

- 3. All surfaces will receive one (1) coat of standard red oxide primer, thickness not to e xceed 3

mils DFT.Ferro Alloy Baghouse System

– Scope of Supply August 5, 2011

MikroPul Pittsb urgh Proposal 0262 Page 26 of 27

Baghouse Housing, Plenums, Poppet Boxes and Hoppers: All external surfaces will be

cleaned in accordance with SSPC SP

- 6. All cleaned surfaces will then receive one (1) coat of high temperature aluminum paint, 3 mils dry film thickness. This coating is designed to withstand continuous exposure to 550° F.

Ductwork and Stack: All external surfaces will be cleaned in accordance with SSPC SP

6. All cleaned surfaces will then receive one (1) coat of High Temperature Aluminum paint, 3 mils dry film thickness. This coating is designed to withstand continuous exposure to 550° F.

Manufacturers’ Supplied Equipment: All motors, compressors, gear reducers, valves, air cylinders, rotary air locks, dampers, electric actuators, man doors, conveyo rs and any other items purchased by MikroPul as a separate component or part of a sub

- assembly will be finished coated per manufacturer’s standards.

Handrails, Ladders, Ladder Cages, Toe Boards: All handrail, ladders, ladder cages and toe boards (except for toe boards at bag suspension and cell plate levels within the baghouse) will be cleaned per SSPC SP

- 6 and painted with one (1) coat of OSHA Safety Yellow, 1.5 mils DFT.

Other Surfaces: All items fabricated from aluminum, stainless steel or any steel that has been galvanized will not be painted.



### 8.0 Optional Installation Services

furnish all labor, miscellaneous materials, consumables, tools, mobile equipment and supervision required for the total turnkey installation of all equipment and material s supplied by MikroPul as stated in MikroPul’s “Scope of Supply” and as follows:

• All receiving, unloading and transporting of all equipment and materials to the

site.

• All mechanical and structural erection.

• Assembly and installation of all equipment.

• Asse mbly and installation of all duct supports and ductwork.

• Leveling, shimming and furnishing all shims.

• All support towers, bents and access platforms.

• Grout under all structural support steel and equipment bases.

• Installation of all air piping from the boun dary limits to all damper actuators and magnehelic gauges.

• Set and perform final fan motor alignment.

• Touch up painting.

• All electrical installation and wiring from new baghouse battery limits.

• Lighting as required with distribution panel.Ferro Alloy Baghouse System

– Scope of Supply August 5, 2011

MikroPul Pittsb urgh Proposal 0262 Page 27 of 27

• Electrical cont rol building.

• Bag leak testing.

• Bag precoating at start

- up.

• Baghouse commissioning.

• Demolition of existing scrubber system.

• Site clean

- up.



### 9.0 Purchaser to Furnish

• All foundations, design, excavation, backfill and installation.

• Clean dry compressed air @ 100PSI to baghouse receiver.

• Disposal of excavated material for equipment foundations (dewatering if required).

• Identification of all site preparation and below ground utilities.

• All fire protection equipment, if required (fire extinguishers).

• All emission testing.

• Control signals for MikroPul system interface.

• Data highway, if required.

• All approvals, licenses and permits as required for construction including, building. permits and environmental regulatory agency permits and approval.

• Supply of a ny required facility drawings, complete and accurate.

• All local and federal taxes as applicable or tax exemption number if such exists for pollution control equipment.

• Water and water piping for spray tower system

• Heat tracing if required

• Adequate lay down area within mutually agreeable distance from baghouse.

• Blasting if required.

• Adequate room for construction trailer within mutually agreeable distance of baghouse erection.

• Temporary power for construction and for trailer.

• Compressed air or nitrogen to b oundary limits.

• Main fan wheel trolleys, hoists and spreader beams.

• Agreement of final tie

- in plan.

• Supply and installation of communication cables, such as, telephone, modem and

LAN.

• All Owner costs associated with visits to the contractor’s facilities or the facilities of its suppliers.

• All existing structure suitability studies for new loads, etc.

• All building steel changes including roof sheeting, flashing, etcFerro 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

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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

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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

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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

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- 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

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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.