Irrespective of our regret to part with natural gas in the blast furnace production it’s inevitable. Transfer of the furnaces to alternative fuel will take place this year.
Several years ago a decision was taken to build a PCI complex on all the blast furnaces. At the end of 2006 a contract was concluded with the German firm “Kuettner” on delivery of equipment for the construction of this complex.
Iron and steel workers of Europe long before Ukraine felt what a harmful influence the cost increase of energy resource had on the economy of enterprises, particularly, the increase of cost of natural gas. This nudged them to improve the production process and introduce energy saving technologies.
One cannot say that PCI installations are a principally new technological solution. Even at our Works several decades ago this technology was tried to be introduced on our blast furnaces. But it could not be accomplished due to several reasons. One of them was because of its large size and imperfection. Introduction of cheap and caloric natural gas in the blast furnace production completely crossed out this idea. When the cost of natural gas skyrocketed the appropriateness of PCI installations was returned to. At that time the PCI installations started to be updated and introduced into production, making them capable of replacing not only natural gas but also reducing the consumption of coke during the process of iron smelting.
According to the feasibility study the PCI complex chosen to be introduced at Zaporizhstal JSC greatly differs from the updated construction, which allows to inject up to 200 kg of coal dust per one ton of pig iron. This installation is designed for the production of 4,5 mln tons of pig iron per year. Such an amount is required to provide capacities of the Works’ converter production.
Economic effect of the introduction of the new installation is expected to reach the level of 200-266 mln UAH. This will allow to pay for the expenditures on its construction in 1,5-1,8 years of its operation.
PCI will allow to completely withdraw from the usage of process natural gas. A considerable economy of coke will also be maintained. This means that the prime cost of pig iron production will reduce.
Works on designing of the complex started in 2007. Construction proper started in 2008. Irrespective of the difficult period for economy and the Works’ production, construction works are being carried out according to schedule. Most of the metal structures for the buildings and the premises of the complex are being manufactured by the staff of the Works. The main processing equipment has already been delivered by firm “Kuettner”. The PCI complex consists of several separate units connected with one another.
– At present all the main processing equipment under the contract with firm “Kuettner” has been delivered to the Works, i.e. 2 mills for grinding coal, ventilators for process and hot blast stove gas, as well as equipment for blast furnace distribution devices, — said the supervisor of the construction works from the Department for Capital Construction V.B. Shalayev.
– The general subcontractor “SMU Zaporozhstalstroy-1” JSC in 2008 accomplished jobs on installation of pile grids of the coal preparation department made of assembly reinforced piles, all the foundations for the frame and also processing equipment. More than 1300 tons of metal structures have been assembled, erection of two mills and 2 ventilators in ventilation room No.2 has started. The bin trestle pile grids and bored piles have been completely installed, foundations for the frame have been accomplished by 90%, 1206 tons of metal structures of the trestle and bins frame have been assembled. Works on the energy trestle with dust delivery pipelines to the distributing devices of the blast furnaces have been fulfilled by 50%. Jobs on mounting of metal structures and walls made of sandwich panels of the distributing devices of blast furnaces Nos. 2,3,4 and 5 have been completely accomplished. The main construction jobs on the nitrogen compressor station have been carried out.
In 2009 a task has been set to finish works on the main technological cycle and to finish the construction in the third quarter.
I would like to mark good work of the Chief Mechanic Department shops who manufactured the metal structures and nonstandard equipment. Deputy Chief Mechanic A.V. Dzyuba is at the head of the construction works.
The work group on construction of the PCI complex is headed by the chief specialist on steel and iron production A.P. Fomenko. One of the main tasks of the group is coordination of the actions of the erection workers of SMU and specialists from firm “Kuettner”.
Unfortunately, due to financial problems questions concerning delivery of material, items and structures are not solved in due time. But the staff of Logistics Department is doing its best to meet the needs of the construction site supplying it with material resources.
The management of the Works gives priority to the duly commissioning of the PCI complex. That is why it demands from all the participants of the construction work not to reduce the pace of construction and to fulfill the set tasks.