Integrated iron and Steel Works “Zaporizhstal” has been systematically revamping production facilities with due account for environment. Around UAH 2.7 billion was invested into development of the Works over 2012-2014. In particular, the Works invested about UAH 486 million into revamping production facilities in 2012, over UAH 553 million in 2013, UAH 1.61 million in 2014. This year “Zaporizhstal” plans to invest about UAH 1.63 million.
Major revamping projects of the Works are: revamping of Sinter Machine No. 1 with high-efficiency gas cleaning, construction of gas-cleaning systems at Sinter Machines No. 2 through 6, large-scale revamping of Blast Furnace No. 4 with installation of aspiration system for the casthouse and the stockhouse gantry, construction and putting into operation of the new hydrochloric acid pickling line with the acid regeneration plant (CPL-4).
In 2013, the Works revamped Sinter Machine No. 1 with up-to-date high-efficiency gas-cleaning equipment, in 2014 it constructed and put into operation gas-cleaning equipment of Sinter Machine No. 2. At the moment, construction of the gas-cleaning systems for Sinter Machines No. 3 through 6 is in progress. After the project on renewal of the gas-cleaning systems at all six Sinter Machines, the Works’ Sinter Shop will reach the level of the best practices in terms of eliminating dust and gases from emissions. Total emissions of the Works will be reduced by 45%. Revamping of all gas-cleaning systems of the Sinter Shop suggests investments of over UAH 845 million.
In 2014, the Works carried out complete revamping of Blast Furnace No. 4 (BF-4), total volume of investments constituted about UAH 950 million. An up-to-date high-efficiency dust-and-gas-cleaning system of the Blast Furnace reduces emissions volume and maintains the output dust concentration of 20 mg/m3, which meets the international standards.
Last year the Works also commissioned a production hydrochloric-acid pickling line (CPL-4) in the Cold Rolling Shop No. 1, which was erected in accordance with European environmental standards. The line was recognized the best industrial facility according to the results of the All-Ukrainian contest of buildings and structures, organized by the State Architectural and Construction Inspectorate of Ukraine. The hydrochloric-acid pickling line is an industrial facility, which is unique in Ukraine. It has full automation of production, which eliminates human factor in equipment operation. CPL-4 output amounts to 1.35 million tonnes of pickled metal per year. After commissioning of the line, the sulfuric acid vapour emissions, as well as discharge of industrial wastewater from the Cold Rolling Shop into the Dnipro River, have ceased completely. Investments into construction amounted to UAH 890 million.
“Zaporizhstal” is planning to revamp steelmaking. The project suggests construction of a complex on hot-rolled coils production with the production capacity of 5 million tonnes per year within the Converter Shop, along with CSPs (Compact Strip Production) and auxiliary production facilities. The investments into the project constitute over USD 1.3 billion. Construction of the Converter Shop will allow the Works to completely abandon outdated open-hearth process and significantly decrease the industrial impact on environment – atmospheric emissions will decrease by 25% from the total amount of the Works emissions. The first stage has been completed at the Works – basic engineering has been performed by the global leading companies in manufacturing of the production equipment, Primetals Technologies Austria GmbH and SMS Siemag. The total cost of works constituted EUR 8.5 million. This year, on 30th of September, the Works concluded a contract with the company Primetals Technologies Ukraine, Ukrainian representative office of Primetals Technologies Austria, and the largest design offices for industrial facilities in Ukraine and CIS – SE “UKRGIPROMEZ” and UkrRTC Energostal – for performance of design and survey work and development of design and estimate documentation for construction of the complex on production of hot-rolled coils within the Converter Shop, of CSPs (Compact Strip Production) and auxiliary production facilities. Total amount of the contract constitutes about UAH 100 million.