The modernization of gas cleaning systems at the sinter plant of Zaporizhstal Steel Works is a significant step towards environmental improvement, involving an investment of over 1.2 billion UAH.
The Zaporizhstal Steel Works, part of the Metinvest Group, has completed an important environmental project: the modernization of gas cleaning systems of sinter machines No. 1-6. Investments in the project amounted to more than 1.2 billion UAH.
"We have reconstructed the gas cleaning systems of sinter machines No. 1-6 consecutively since 2012, under the conditions of the current production. During the development and implementation of the project, we looked up to the most modern world experience: 95% of the gas cleaning systems installed at modern metallurgical plants in China, Japan, the USA, and Europe use bag filters, which are the most effective cleaning method. This technology is also used for gas cleaning of the Zaporizhstal sinter plant," said Rostyslav Shurma, CEO of the Works.
In April 2018, the Works completely finished modernization of the gas cleaning systems of sinter machines No. 1-6, which provide air purification from dust up to 30 mg/m3 and from sulphurous anhydride below 400 mg/m3, meeting European emission standards, and also allowing for a step-by-step reduction of discharge of slime water from the sinter plant cycle.
"The new gas cleaning systems of the sinter plant will reduce dust emissions by 90% and emissions of sulfur oxides by 50%. The implementation of this decision has enabled us to fulfill our obligations to reduce the technogenic burden on the region. For Zaporizhstal, it is a 100% ecological project, with no economic component," pointed out Rostyslav Shurma.
In the technology of air cleaning using bag filters, an exhauster is utilized to provide both air supply to the sinter machine for sintering the agglomerate and further transportation of contaminated air to bag filters. The process is designed such that shutting down the exhauster will lead to a stoppage in the production of agglomerate and loss of production. Stopping gas cleaning is only possible if the entire sintering machine is halted for maintenance.
The automated control system of the technological process completely excludes the human factor. Operators in the control room perform only control-monitoring functions. As a result, specialists in the monitoring and control of gas cleaning have undergone specialized training concerning the standards of work on new environmental equipment.
Each sinter machine is equipped with emission control sensors that, in real-time with millisecond discreteness, display the efficiency of gas cleaning equipment. The online monitoring system not only controls the final concentration of pollutant emissions at the outlet to the atmosphere but also allows for operational management of the cleaning process, ensuring the reliability and efficiency of gas cleaning equipment operation.
Let us remind you that from 2012 to 2017, Zaporizhstal invested approximately 8.8 billion UAH in environmental modernization. Among the main environmental projects of the Works are complete ecological modernization of the sinter plant, including the construction of new high-efficiency gas cleaning systems on all six sinter machines, as well as large-scale reconstruction of blast furnace No. 4 with the installation of an aspiration system for the casting yard and charging bay, construction of a new continuous pickling line in the cold rolling shop No. 1, and large-scale reconstruction of blast furnace No. 3. All new and reconstructed facilities of the Works are integrated into a unique system of visualization and online monitoring of technological processes named "Enterprise in your hand."