PJSC “Zaporizhstal” is a company with a full metallurgical cycle, which occupies a leading place in steel production in Ukraine, in the export of metal products to more than 50 countries of the world, as well as in tax deductions. In 2018, the Works increased tax transfers to the budget of Ukraine, sending more than 3.8 billion hryvnias to the state treasury.
Zaporizhstal is:
- The third in Ukraine in terms of metal production volumes
- Every fifth ton of Ukrainian metal produced at the Works
- 15% of currency earnings of Ukraine
- more than 250 million tons of pig iron smelted by “Zaporizhstal” for its 85-year history
- More than 60 European countries-consumers of our rolled-stock
- The Works’ area – over 550 hectares or 777 football fields
- A collective – over 11 000 employees
- The energy consumption of production was halved – from 2012, natural gas consumption was reduced from 330 million cubic meters per year to 163 million cubic meters in 2018
- 70% of the Works’ exported products
- Annual production of3 million tons of pig iron, 4.1 million tons of steel, 3.5 million tons of rolled-stock
- Over UAH100 million allocated for the city’s infrastructure development
In 2018, Zaporizhstal PJSC delivered over 670 thousand tonnes of metal products to customers by water transport through the Zaporizhzhya river port.
The Works systematically modernizes its production facilities, paying special attention to environmental issues. Since 2012, it has been allocated about UAH10.6 billion to the environmental modernization and reconstruction of the Works.
The main environmental projects of recent years have been the modernization of the gas cleaning systems of all six sintering machines of the Works, the large-scale reconstruction of the blast furnace No. 3, the overhauls of blast furnaces: 4 and 5, the construction of a new cooling tower. According to the results of ecological modernization, Zaporizhstal was recognized as the winner in the nomination “The Leader of Comprehensive Green Modernization” within the framework of the “EKOTRANSFORMATION-2018” competition.
In 2019, within the framework of ecological modernization, a modern complex for intercepting industrial stormwater runoff has already been launched. It will reduce the discharge of industrial water in the Dnieper by 5 million m3 per year. Investment in the project amounted to UAH58.5 million.
Zaporizhstal also continues in 2019 a program of locomotive fleet remotorization. For these purposes, the Works will allocate UAH50 million. The Works received a production certificate confirming the high qualification of locomotive depot personnel and the high quality of repair of diesel locomotives.
One of the most important events for the Works in 2018 was the 85th anniversary of the enterprise. At the gala evening in honor of the anniversary, the Works’ records were presented, which entered the book of records of Ukraine: for the fastest reconstruction of the blast furnace and for the longest environmental campaign “Let’s save the Dnieper together!”
HISTORY
2012 was decisive for the subsequent development of innovative PJSC “Zaporizhstal”. On enterprise comes a new, effective owner – Metinvest Group.
Director General of the Company appointed Rostislav Shurma having an effective experience in the metallurgical enterprises of Metinvest.
The PJSC “Zaporizhstal” developed and implemented a program to improve the efficiency and modernization of production, improve working conditions and safety. Since August 2012, the mill is marked increase in production efficiency, reduce production costs. Works out at break-even level of production.
PJSC “Zaporizhstal” actively ecological modernization of production assets. The company is consistently implementing all environmental protection activities under a tripartite agreement between the combine, Zaporizhzhya Regional Council and the Ministry of Ecology and Natural Resources of Ukraine.
Designating one of its key priorities improving industrial safety, PJSC “Zaporizhstal” increased social investment programs implemented in the enterprise. Since August 2012, for employees purchased new clothing, personal protection on hot areas in the shops are air-conditioned.
In October 2012, after a long break PJSC “Zaporizhstal” resumed cooperation with Zaporizhzhya river port for the shipment of their products.
In December 2012 the PJSC “Zaporizhstal” implemented a major investment project – part of the modern high-tech job base coal storage complex installation of pulverized coal injection in blast furnaces. Full amount of investment in the project IFB – about 1 billion UAH., Including BSU – 350 million UAH.
Implementation of the project has allowed PJSC IFB “Zaporizhstal” completely abandon the use of blast furnace production of natural gas, to reduce coke consumption.
In January 2013 signed a memorandum of cooperation with the Athletics Federation of Ukraine. Combine sets monthly scholarships leading athletes Zaporozhye region – Olympic champions and medalists, world champions and Europe, among them Maria Belt, Olesya Povkh Aleksey Kasyanov, Oleg Stepko Anna Gatsko Yuri Kushniruk, Cyril Dolgov, Bogdan Panchenkov Skobelskaya Alina, Anna Melnichenko.
In 2013, in Kiev, with the support of PJSC “Zaporizhstal”, a competition of social projects “We – a city” under corporate social programs of Metinvest Group. Fourteen winners of the contest Works has awarded grants totaling $ 700 thousand UAH. The city is successful implementation of all social projects.
In May 2013 the PJSC “Zaporizhstal” completed a large-scale environmental project for the modernization of sinter production. Commissioned a new set of hardware – sinter machine number 1, a high-tech scrubbing with two powerful electrostatic, exhauster office and compressor station. Environmental effect – reducing emissions of dust and gas in the atmosphere at a level up to 10% of the total emissions of the plant. Investment in the project – 240 million UAH.
At the opening ceremony of sinter complex was attended by President of Ukraine Viktor Yanukovych and the owner of SCM, the largest shareholder of the plant, Rinat Akhmetov.
During the visit to the plant Rinat Akhmetov visited the cold rolling shop number 1 and the construction of a new pickling line PJSC “Zaporizhstal”.
In July 2013, on the eve of the Day of Metallurgist Presidential Decree seven workers PJSC “Zaporizhstal” awarded honorary titles and awards. Honorary title “Honored Metallurgist of Ukraine ” was awarded to deputy chief of department of PJSC ” Zaporizhstal” Andrei Kazmin, steel caster shop PJSC “Zaporizhstal” Oleg Kucherenko and roller shop PJSC “Zaporizhstal” Alexander Sklar. Awarded the Order “For merits » II degree roller shop PJSC “Zaporizhstal” Alexander Simonenko, the Order “For merits » III degree : Aglomeratchikov shop PJSC “Zaporizhstal” Nikolai Moscovkin carver shop PJSC “Zaporizhstal” Andrew Salyakin, chief MK “Zaporizhstal” Alexander Fomenko.
In 2013 the gas purification of sinter machine No.1 was reconstructed. In 2014, the upgraded Blast Furnace No.4 built hydrochloric acid pickling line construction at the cold Rolling Mill No.1 and gas-cleaning systems at Sinter Machine № 2. Moreover, the modernization program of the works includes gas purifying reconstruction of sinter machines No.3 –No.6, Blast Furnaces No.3 and No.5 renovation repairs, construction of the new turbo blower. For these purposes is planned to allocate about 200 mln. USD. The enterprise has a long term plan to pass to the BOF steelmaking process.
For the 2013-2014 years, «Zaporizhstal» Steel Works had invested in ecological modernization about UAH 2.25 billiard: in 2013 – more than UAH 600 million, in 2014 – over UAH 1.655 million.
In 1994 – the first time in practice broadband operation mills – at PJSC “Zaporizhstal” energy-saving technology introduced direct (transit) rolling slabs, without preheating in reheat furnaces. At the same time in the production of 1 ton of product achieved a reduction in natural gas consumption by 75%.
“Nugget – slab – roll” – the first time in Ukraine under the scheme in 1997-1998 PJSC “Zaporizhstal” releases a new product for the pipe industry in the country : hot rolled coils weighing up to 16 tons Up to this maximum coil weight does not exceed 8 tonnes
In 2000, in the blooming shop PJSC “Zaporizhstal” is included in the automatic control system of heating bars in soaking pits – a significant energy saving measures. Consumption of fuel in the production process is reduced to 5 kg / t, also reduced the waste of metal – 2 kg / ton of product.
In 2003, PJSC “Zaporizhstal” put into effect the quality management system, designed to bring quality products in line with international standards.
In 2008, PJSC “Zaporizhstal” developed integrated quality management system, environment and safety, confirmed by a certificate of “Bureau Veritas Ukraine”.
Integrated quality management system, environment and labor protection PJSC “Zaporizhstal” meets the requirements of ISO 9001, ISO 14001, OHSAS 18001 and ILO-OSH 2001.
In 2008, the blast furnace PJSC “Zaporizhstal” begins construction of plants for pulverized coal injection. Installation is included in the job in October 2011.
Full amount of investment in the project IFB PJSC “Zaporizhstal” was the order of 1 billion USD., Including the construction of coal storage base – 350 million UAH.
After the introduction of the PJSC “Zaporizhstal” pulverized coal injection technology – since October 2011 – injection of natural gas in blast furnaces ceased. Significantly reduced coke consumption in the smelting of 1 ton of pig iron.
In 2004, PJSC “Zaporizhstal” enacts reconstructed DP number 2, with the installation of devices with shaftless dome burners. Putting it into operation will allow the company to decommission DP number 1, which began in 1933, PJSC “Zaporizhstal”.
In 2009, the protected island Khortytsya offers historical and cultural complex “Zaporozhye”. General sponsor of the construction is PJSC “Zaporizhstal”, invest in construction of more than 12 mln.
In December 1952 PJSC “Zaporizhstal” – the first time in the country – the first produced by melting oxygen blowing, their technology was worked out together with the specialists of the Central Research Institute of Ferrous Metallurgy.
Since 1954, PJSC “Zaporizhstal” moves to the industrial application of oxygen in steel production. The average duration of melting in this decreases by 2 hours, and per square meter of hearth Steelmakers removed 100 tons of steel more.
In 1956, the country goes to the cinema screens cult film “Spring on Zarechnaya Street”, where the role of steelworker Sasha Savchenko removed actor Nikolai Rybnikov. Filming of the movie took place in MK “Zaporizhstal” and get used to the way of helping young steelworker Rybnikovu steelmaker Zaporizhstal Gregory Pometun. In 1953, when Gregory Pometun was 23, he had already led the youth team and won the title of “Best steelworker Soviet Union.” Hero of Socialist Labor title Grigory was given when he was 28 years old.
In 1957 PJSC “Zaporizhstal” – the first time in the country – the production of hot-rolled sheet is translated into a method.
In 1959, PJSC “Zaporizhstal” – the first time in the country – Production of cold-formed profiles. Machine-building enterprises of the country received the blank that do not require additional treatment.
In 1960, in blast furnaces PJSC “Zaporizhstal” mastered ferromanganese smelting. Its production is less coke and manganese ore than in other plants. Zaporizhstal ferromanganese allowed to begin production of new high-strength steels for the first artificial satellites.
In 1962, PJSC “Zaporizhstal” comes into operation foundry. At that time – the biggest in Europe, where the molds used for the production of cast iron the first heat. First in the world to a new foundry for the production of molds and cores used zhidkopodvizhnye practical self-hardening mixtures – effective for making large molds and cores.
Soon zhidkopodvizhnyh license to manufacture self-hardening mixtures at PJSC “Zaporizhstal” acquire steel companies of England, France and Japan – for use in their factories. Chief foundry Andrey Tkachenko, under whose leadership the commercial production zhidkopodvizhnyh self-hardening mixtures, was awarded the Lenin – the most prestigious award of the country.
In April 1963, the PJSC “Zaporizhstal” included in the first stage of cold rolling mill number 3. The mill ” 2800 ” is rolling large sheets of stainless steel and complexly.
In 1965, PJSC “Zaporizhstal” starts central laboratory computing. Subsequently, the first computer center enterprise in domestic steel enacts control complex ” Listoprokat “, which tracks the movement of the metal in real time.
In January 1971, for high production performance PJSC “Zaporizhstal” was awarded the Order of the October Revolution.
In 1974, steel production PJSC “Zaporizhstal” commissioned the first in Ukraine tandem furnace ACD -1, the performance of which is 2.5 times the performance of conventional ovens.
In September 1977, in steelmaking PJSC “Zaporizhstal” mastered the method for slide metal casting, thanks to the use of the most modern steel teeming ladles at the time sliding shutters.
“Give us a hundred million” – the motto of working group “Iron and Steel” in 1978.
February 3, 1978 on “Iron and Steel” was smelted 100 millionth ton of steel, and on September 26 – the 100-millionth ton of iron from the date of the start of blast furnace number 1.
June 18, 1983 on a continuous rolling mill MK chetyrehkletevom “Zaporizhstal” was rolled 100 millionth ton of rolled steel.
In the 1990s – the formation of the national economy – PJSC “Zaporizhstal” actively forming marketing, is very active in the search for new markets. By 1994, the PJSC “Zaporizhstal” commercial production of new types of 19 hot-and cold-rolled sheet / tape for the engineering industry in Ukraine.
During the 1990s, the PJSC “Zaporizhstal” are processes of modernization and automation of transport services. In 1992, East railway station is commissioned automatic weight control loading wagons.
The Great Patriotic War of 1941-1945 interrupts the development of PJSC “Zaporizhstal”. August 18, 1941 the work of the plant was shut down completely.
In October 1941, under difficult conditions approaching front was completed dismantling basic equipment PJSC “Zaporizhstal” in the heartland sent more than 50 tons of unique metallurgical equipment. Later it was installed in factories in Russia, on Magnitogorsk Zaporizhstal martenovtsy mastered armor steel smelting furnaces in heavy main vault.
Postwar reconstruction PJSC “Zaporizhstal” becomes a priority for the country. In June 1947, included in the system restored DP number 3, June 1948 – DP number 4. This unit became the country’s first all-welded blast furnace. Welding hull number 4 DP specialists carried out in just 34 days.
By December 1949 PJSC “Zaporizhstal” resumed steelmaking and overlooked the prewar production level.
After 1945, the economy is in dire need of sheet steel for the automotive industry. All attention was drawn to Zaporizhstal recovery rolling production. In July 1947, the first laminated slabbing ingots recovered in August – a continuous hot rolling mill.
In November 1948 at the plant mastered rolling broadband structural autoleaf. He used the Gorky Automobile Plant in the production of the first “national” car “Victory”.
For the development of thin cold-rolled sheet production, urgently needed for automobile and agricultural machinery, PJSC “Zaporizhstal” in 1947 was awarded the Order of Lenin.
In August 1951, the PJSC “Zaporizhstal” is included in the operation of the sinter plant.
In December 1952 PJSC “Zaporizhstal” – the first time in the country – the first produced by melting oxygen blowing, their technology has been tested in conjunction with specialists from the Central Research Institute of Ferrous Metallurgy.
In May 1929 the government decided to build a large industrial complex Zaporozhye ferrous and nonferrous metallurgy. Becomes the main construction Dnieper industrial complex where the original plant was part of sheet steel – modern PJSC “Zaporizhstal”.
Construction of “Iron and Steel” will start in January 1931. The project developed a new plant -Union Institute “Gipromez”.
In October 1932 at the industrial site of the future IC “Iron and Steel” delivers electricity just built DnieproGES, the largest hydroelectric power plant at the time of the country.
November 16, 1933 – the birthday of PJSC “Zaporizhstal”. The enterprise first blast furnace blow – it is at that time the most powerful in Ukraine, its volume – 960 cubic meters.
The new plant becomes Europe’s largest steel mill, with a design capacity of 1.2 million tons of iron and 1.4 million tons of steel.
In 1934, the PJSC “Zaporizhstal” is the work of the DP number 2, and in 1938 – DP number 3, while the largest in the world, its volume of 1300 cubic meters.
In 1935 the PJSC “Zaporizhstal” comes into operation the first open-hearth furnace. After it has entered into service just two open hearth furnaces – the first time in the global steel industry.
In 1937, the company enters into operation the first domestic slabbing. He becomes the first not only in the country but also in Europe, and only the third in the world.
In 1938, PJSC “Zaporizhstal” is the work of Europe’s first continuous hot rolling sheet steel. By its power and bandwidth new shop is unique in Europe.
In 1939 part of the work of the cold rolling shop № 1.
By 1940 PJSC “Zaporizhstal” produces 70 percent of all steel sheet is produced while in the country. From this point on agricultural engineering and automotive country got thin sheet products produced domestically.
- 2012–2015
-
2012 was decisive for the subsequent development of innovative PJSC “Zaporizhstal”. On enterprise comes a new, effective owner – Metinvest Group.
Director General of the Company appointed Rostislav Shurma having an effective experience in the metallurgical enterprises of Metinvest.
The PJSC “Zaporizhstal” developed and implemented a program to improve the efficiency and modernization of production, improve working conditions and safety. Since August 2012, the mill is marked increase in production efficiency, reduce production costs. Works out at break-even level of production.
PJSC “Zaporizhstal” actively ecological modernization of production assets. The company is consistently implementing all environmental protection activities under a tripartite agreement between the combine, Zaporizhzhya Regional Council and the Ministry of Ecology and Natural Resources of Ukraine.
Designating one of its key priorities improving industrial safety, PJSC “Zaporizhstal” increased social investment programs implemented in the enterprise. Since August 2012, for employees purchased new clothing, personal protection on hot areas in the shops are air-conditioned.
In October 2012, after a long break PJSC “Zaporizhstal” resumed cooperation with Zaporizhzhya river port for the shipment of their products.
In December 2012 the PJSC “Zaporizhstal” implemented a major investment project – part of the modern high-tech job base coal storage complex installation of pulverized coal injection in blast furnaces. Full amount of investment in the project IFB – about 1 billion UAH., Including BSU – 350 million UAH.
Implementation of the project has allowed PJSC IFB “Zaporizhstal” completely abandon the use of blast furnace production of natural gas, to reduce coke consumption.
In January 2013 signed a memorandum of cooperation with the Athletics Federation of Ukraine. Combine sets monthly scholarships leading athletes Zaporozhye region – Olympic champions and medalists, world champions and Europe, among them Maria Belt, Olesya Povkh Aleksey Kasyanov, Oleg Stepko Anna Gatsko Yuri Kushniruk, Cyril Dolgov, Bogdan Panchenkov Skobelskaya Alina, Anna Melnichenko.
In 2013, in Kiev, with the support of PJSC “Zaporizhstal”, a competition of social projects “We – a city” under corporate social programs of Metinvest Group. Fourteen winners of the contest Works has awarded grants totaling $ 700 thousand UAH. The city is successful implementation of all social projects.
In May 2013 the PJSC “Zaporizhstal” completed a large-scale environmental project for the modernization of sinter production. Commissioned a new set of hardware – sinter machine number 1, a high-tech scrubbing with two powerful electrostatic, exhauster office and compressor station. Environmental effect – reducing emissions of dust and gas in the atmosphere at a level up to 10% of the total emissions of the plant. Investment in the project – 240 million UAH.
At the opening ceremony of sinter complex was attended by President of Ukraine Viktor Yanukovych and the owner of SCM, the largest shareholder of the plant, Rinat Akhmetov.
During the visit to the plant Rinat Akhmetov visited the cold rolling shop number 1 and the construction of a new pickling line PJSC “Zaporizhstal”.
In July 2013, on the eve of the Day of Metallurgist Presidential Decree seven workers PJSC “Zaporizhstal” awarded honorary titles and awards. Honorary title “Honored Metallurgist of Ukraine ” was awarded to deputy chief of department of PJSC ” Zaporizhstal” Andrei Kazmin, steel caster shop PJSC “Zaporizhstal” Oleg Kucherenko and roller shop PJSC “Zaporizhstal” Alexander Sklar. Awarded the Order “For merits » II degree roller shop PJSC “Zaporizhstal” Alexander Simonenko, the Order “For merits » III degree : Aglomeratchikov shop PJSC “Zaporizhstal” Nikolai Moscovkin carver shop PJSC “Zaporizhstal” Andrew Salyakin, chief MK “Zaporizhstal” Alexander Fomenko.
In 2013 the gas purification of sinter machine No.1 was reconstructed. In 2014, the upgraded Blast Furnace No.4 built hydrochloric acid pickling line construction at the cold Rolling Mill No.1 and gas-cleaning systems at Sinter Machine № 2. Moreover, the modernization program of the works includes gas purifying reconstruction of sinter machines No.3 –No.6, Blast Furnaces No.3 and No.5 renovation repairs, construction of the new turbo blower. For these purposes is planned to allocate about 200 mln. USD. The enterprise has a long term plan to pass to the BOF steelmaking process.
For the 2013-2014 years, «Zaporizhstal» Steel Works had invested in ecological modernization about UAH 2.25 billiard: in 2013 – more than UAH 600 million, in 2014 – over UAH 1.655 million.
- 1991-2011
-
In 1994 – the first time in practice broadband operation mills – at PJSC “Zaporizhstal” energy-saving technology introduced direct (transit) rolling slabs, without preheating in reheat furnaces. At the same time in the production of 1 ton of product achieved a reduction in natural gas consumption by 75%.
“Nugget – slab – roll” – the first time in Ukraine under the scheme in 1997-1998 PJSC “Zaporizhstal” releases a new product for the pipe industry in the country : hot rolled coils weighing up to 16 tons Up to this maximum coil weight does not exceed 8 tonnes
In 2000, in the blooming shop PJSC “Zaporizhstal” is included in the automatic control system of heating bars in soaking pits – a significant energy saving measures. Consumption of fuel in the production process is reduced to 5 kg / t, also reduced the waste of metal – 2 kg / ton of product.
In 2003, PJSC “Zaporizhstal” put into effect the quality management system, designed to bring quality products in line with international standards.
In 2008, PJSC “Zaporizhstal” developed integrated quality management system, environment and safety, confirmed by a certificate of “Bureau Veritas Ukraine”.
Integrated quality management system, environment and labor protection PJSC “Zaporizhstal” meets the requirements of ISO 9001, ISO 14001, OHSAS 18001 and ILO-OSH 2001.
In 2008, the blast furnace PJSC “Zaporizhstal” begins construction of plants for pulverized coal injection. Installation is included in the job in October 2011.
Full amount of investment in the project IFB PJSC “Zaporizhstal” was the order of 1 billion USD., Including the construction of coal storage base – 350 million UAH.
After the introduction of the PJSC “Zaporizhstal” pulverized coal injection technology – since October 2011 – injection of natural gas in blast furnaces ceased. Significantly reduced coke consumption in the smelting of 1 ton of pig iron.
In 2004, PJSC “Zaporizhstal” enacts reconstructed DP number 2, with the installation of devices with shaftless dome burners. Putting it into operation will allow the company to decommission DP number 1, which began in 1933, PJSC “Zaporizhstal”.
In 2009, the protected island Khortytsya offers historical and cultural complex “Zaporozhye”. General sponsor of the construction is PJSC “Zaporizhstal”, invest in construction of more than 12 mln.
- 1952-1990
-
In December 1952 PJSC “Zaporizhstal” – the first time in the country – the first produced by melting oxygen blowing, their technology was worked out together with the specialists of the Central Research Institute of Ferrous Metallurgy.
Since 1954, PJSC “Zaporizhstal” moves to the industrial application of oxygen in steel production. The average duration of melting in this decreases by 2 hours, and per square meter of hearth Steelmakers removed 100 tons of steel more.
In 1956, the country goes to the cinema screens cult film “Spring on Zarechnaya Street”, where the role of steelworker Sasha Savchenko removed actor Nikolai Rybnikov. Filming of the movie took place in MK “Zaporizhstal” and get used to the way of helping young steelworker Rybnikovu steelmaker Zaporizhstal Gregory Pometun. In 1953, when Gregory Pometun was 23, he had already led the youth team and won the title of “Best steelworker Soviet Union.” Hero of Socialist Labor title Grigory was given when he was 28 years old.
In 1957 PJSC “Zaporizhstal” – the first time in the country – the production of hot-rolled sheet is translated into a method.
In 1959, PJSC “Zaporizhstal” – the first time in the country – Production of cold-formed profiles. Machine-building enterprises of the country received the blank that do not require additional treatment.
In 1960, in blast furnaces PJSC “Zaporizhstal” mastered ferromanganese smelting. Its production is less coke and manganese ore than in other plants. Zaporizhstal ferromanganese allowed to begin production of new high-strength steels for the first artificial satellites.
In 1962, PJSC “Zaporizhstal” comes into operation foundry. At that time – the biggest in Europe, where the molds used for the production of cast iron the first heat. First in the world to a new foundry for the production of molds and cores used zhidkopodvizhnye practical self-hardening mixtures – effective for making large molds and cores.
Soon zhidkopodvizhnyh license to manufacture self-hardening mixtures at PJSC “Zaporizhstal” acquire steel companies of England, France and Japan – for use in their factories. Chief foundry Andrey Tkachenko, under whose leadership the commercial production zhidkopodvizhnyh self-hardening mixtures, was awarded the Lenin – the most prestigious award of the country.
In April 1963, the PJSC “Zaporizhstal” included in the first stage of cold rolling mill number 3. The mill ” 2800 ” is rolling large sheets of stainless steel and complexly.
In 1965, PJSC “Zaporizhstal” starts central laboratory computing. Subsequently, the first computer center enterprise in domestic steel enacts control complex ” Listoprokat “, which tracks the movement of the metal in real time.
In January 1971, for high production performance PJSC “Zaporizhstal” was awarded the Order of the October Revolution.
In 1974, steel production PJSC “Zaporizhstal” commissioned the first in Ukraine tandem furnace ACD -1, the performance of which is 2.5 times the performance of conventional ovens.
In September 1977, in steelmaking PJSC “Zaporizhstal” mastered the method for slide metal casting, thanks to the use of the most modern steel teeming ladles at the time sliding shutters.
“Give us a hundred million” – the motto of working group “Iron and Steel” in 1978.
February 3, 1978 on “Iron and Steel” was smelted 100 millionth ton of steel, and on September 26 – the 100-millionth ton of iron from the date of the start of blast furnace number 1.
June 18, 1983 on a continuous rolling mill MK chetyrehkletevom “Zaporizhstal” was rolled 100 millionth ton of rolled steel.
In the 1990s – the formation of the national economy – PJSC “Zaporizhstal” actively forming marketing, is very active in the search for new markets. By 1994, the PJSC “Zaporizhstal” commercial production of new types of 19 hot-and cold-rolled sheet / tape for the engineering industry in Ukraine.
During the 1990s, the PJSC “Zaporizhstal” are processes of modernization and automation of transport services. In 1992, East railway station is commissioned automatic weight control loading wagons.
- 1941-1952
-
The Great Patriotic War of 1941-1945 interrupts the development of PJSC “Zaporizhstal”. August 18, 1941 the work of the plant was shut down completely.
In October 1941, under difficult conditions approaching front was completed dismantling basic equipment PJSC “Zaporizhstal” in the heartland sent more than 50 tons of unique metallurgical equipment. Later it was installed in factories in Russia, on Magnitogorsk Zaporizhstal martenovtsy mastered armor steel smelting furnaces in heavy main vault.
Postwar reconstruction PJSC “Zaporizhstal” becomes a priority for the country. In June 1947, included in the system restored DP number 3, June 1948 – DP number 4. This unit became the country’s first all-welded blast furnace. Welding hull number 4 DP specialists carried out in just 34 days.
By December 1949 PJSC “Zaporizhstal” resumed steelmaking and overlooked the prewar production level.
After 1945, the economy is in dire need of sheet steel for the automotive industry. All attention was drawn to Zaporizhstal recovery rolling production. In July 1947, the first laminated slabbing ingots recovered in August – a continuous hot rolling mill.
In November 1948 at the plant mastered rolling broadband structural autoleaf. He used the Gorky Automobile Plant in the production of the first “national” car “Victory”.
For the development of thin cold-rolled sheet production, urgently needed for automobile and agricultural machinery, PJSC “Zaporizhstal” in 1947 was awarded the Order of Lenin.
In August 1951, the PJSC “Zaporizhstal” is included in the operation of the sinter plant.
In December 1952 PJSC “Zaporizhstal” – the first time in the country – the first produced by melting oxygen blowing, their technology has been tested in conjunction with specialists from the Central Research Institute of Ferrous Metallurgy.
- 1929 - 1940
-
In May 1929 the government decided to build a large industrial complex Zaporozhye ferrous and nonferrous metallurgy. Becomes the main construction Dnieper industrial complex where the original plant was part of sheet steel – modern PJSC “Zaporizhstal”.
Construction of “Iron and Steel” will start in January 1931. The project developed a new plant -Union Institute “Gipromez”.
In October 1932 at the industrial site of the future IC “Iron and Steel” delivers electricity just built DnieproGES, the largest hydroelectric power plant at the time of the country.
November 16, 1933 – the birthday of PJSC “Zaporizhstal”. The enterprise first blast furnace blow – it is at that time the most powerful in Ukraine, its volume – 960 cubic meters.
The new plant becomes Europe’s largest steel mill, with a design capacity of 1.2 million tons of iron and 1.4 million tons of steel.
In 1934, the PJSC “Zaporizhstal” is the work of the DP number 2, and in 1938 – DP number 3, while the largest in the world, its volume of 1300 cubic meters.
In 1935 the PJSC “Zaporizhstal” comes into operation the first open-hearth furnace. After it has entered into service just two open hearth furnaces – the first time in the global steel industry.
In 1937, the company enters into operation the first domestic slabbing. He becomes the first not only in the country but also in Europe, and only the third in the world.
In 1938, PJSC “Zaporizhstal” is the work of Europe’s first continuous hot rolling sheet steel. By its power and bandwidth new shop is unique in Europe.
In 1939 part of the work of the cold rolling shop № 1.
By 1940 PJSC “Zaporizhstal” produces 70 percent of all steel sheet is produced while in the country. From this point on agricultural engineering and automotive country got thin sheet products produced domestically.
PROGRESS
CONTINUOUS IMPROVEMENT
The continuous improvement program has begun at PJSC “Zaporizhstal” in August 2012.
Continuous improvement is a comprehensive systematic approach to the solution of industrial problems. It includes process optimization for decreasing consumption of raw materials, materials, production cycle time and improvement of product quality.
The program objective is to achieve the state, in which every employee could discover the existing problems, identify their cause and implement systematic solutions for elimination and prevention of these problems.
Key areas of work:
• bonus system in accordance with KPI, developed and implemented in subdivisions of the Works. The system is being constantly improved in order to increase performance;
• lists of controlled parameters of technological process and equipment, developed for improvement of product quality;
• process optimization through the series of operational improvements, carried out in subdivisions of the Works;
• systematic analysis of deviation reasons by employees of all levels with development of correcting and preventive measures;
• proposal submission system and work of continuous improvement teams; •
“School of Industrial Managers” on the base of the continuous improvement department of “Zaporizhstal”
• «5S» – workplace arrangement system, which substantially improves performance and controllability of the processes, improves corporate culture and increases labour efficiency.
The continuous improvement system at PJSC “Zaporizhstal” has a range of prospects, including:
– Implementation of ТРМ – system of total productive maintenance, in which process and maintenance staff participate jointly;
– Implementation of SMED – changeover of the equipment with continuous increase of its performance;
ENERGY SAVING
One of the area of priority of PJSC “Zaporizhstal” is the increasing of energy efficiency and production resources conservation.
Energy management system of the Steel Works was certified for the compliance with international standard ISO 50001 that allows achieving significant energy savings by applying best management practices without significant investment. Energy management system allows reducing the cost and energy intensity of products, energy sources costs, improves waste management and ensures the compliance with the requirements for reducing greenhouse gas emissions.
Amongst the key successfully implemented by PJSC “Zaporizhstal” energy conservation projects is putting into operation a pulverized coal injection plant, which allowed the Steel Works completely to stop using natural gas in blast furnace production.
In spring 2016 PJSC “Zaporizhstal” together with “Zaporozhkoks” implemented a project for the secondary gases exchange. Nowadays a cheaper analogue of natural gas is used in sinter plant, power plant, rolling mill shops (blooming shop, hot strip rolling shop) – mixed coke-oven and blast-furnace gas and mixed natural gas and blast-furnace gas.
Therefore in 2016 the Steel Works record decreased the consumption of natural gas in production to 160 million m3, which is 22% (44 million m3) lower than 2015 values (204 million m3), and this is an obvious success. The plan for the future is to changeover from open-hearth furnace method of steelmaking to converter method. This will allow achieving an even more significant energy-conserving effect
In 2017, under the project implementation for the secondary gases exchange between “Zaporizhstal” and “Zaporozhkoks”, a gas flow adjuster of waste-heat boiler РК85-1 of coking plant was modernized. This allowed increasing the volume of coke-oven gas supplies to Zaporizhstal to 8 million m3 per year, reducing natural gas consumption by 4 million m3per year. The economic benefit will allow Zaporizhstal to save UAH 26 million per year additionally.
A lot of attention is paid to the efficiency of electricity and other energy resources at the Steel Works.
As an example, there is a popular System of bids submission at the Steel Works. All rational ideas of “Zaporizhstal” employees are being introduced into production. The authors of the implemented projects are rewarded. In 2016, the economic benefit of the System amounted to UAH 215 million.
INVESTMENTS AND INNOVATIONS
Zaporizhstal actively upgrading of existing equipment, innovates constantly increasing volume and efficiency, improving product quality, reducing costs. The priority areas are retooling:
- energy and resource efficiency;
- improving the quality and range of steel products;
- to increase production;
- protection of the environment.
Realized investment projects 2012-2013years:
- commissioning of the coal storage base in the complex installation of PCI in blast furnaces,
- reconstruction aglomashiny №1 with the construction of a new efficient gas cleaning unit.
Zaporizhstal implementing modernization projects : – Construction of a new line chlorohydrin acid etching with hydrochloric acid regeneration plant . Commissioning of the new line chlorohydrin acid etching and URSC will reduce emissions by 83% sulfuric acid vapor and completely eliminate discharges into the river Dnepr plant from cold rolling mill, as well as to increase the production of etched metal with 212 thousand tons / year, resulting in the regeneration process hydrochloric acid is a byproduct of the production of 16,8 thusand tons / year of iron oxide , which allow to partially replace the charge in the manufacture of sinter plant. The project budget is 730 million UAN. – Refurbishment of DP- 4. The reconstruction project provides new aspiration system casthouse and Stock house assembling, replacing the use of natural gas in the pulverized coal. As a result of reconstruction of the DP -4 increase furnace capacity to 1112 thousand tons of pig iron per year (since 1052 tonnes). Aspiration installation casthouse and stock house assembling furnace includes shelter gutters and local outlets with cleaning dust-gas mixture in a bag filter, which provides a degree of cleaning up to European standards. Investment will be about 600 million UAN. – Reconstruction of gas cleaning aglomashine №2. Reconstruction of gas cleaning will reduce the dust content to 50 mg/m3; of sulfur dioxide – to 400 mg/m3 and allow phases to reduce dumping of sludge from water reverse cycle sinter plant. Through this event, the environmental situation in Zaporozhye improve. The project budget is 80 million UAN.
STRUCTURE OF PRODUCTION
Production capacity “Zaporizhstal” are:
- Sinter Shop (6 agglomachines),
- Blast furnace (4 blast furnaces),
- Open-hearth furnace (7 open-hearth furnaces and 1 tandem furnaces),
- Preparation plant compositions,
- Crimping shop,
- Workshop hot rolling the thin sheet,
- Cold rolling shop № 1,
- Cold rolling shop № 3.
In sintering shop main plant produced iron ore sinter. Virtually all production processes are automated agglomerate.
Blast furnace smelted annually about 3.5 million tons of pig iron/year. A distinctive feature of iron production MK “Zaporizhstal” is a low content of sulfur and phosphorus.
Production of open-hearth furnace is about 4.0 million tons of steel / year. Hearth furnaces use natural gas. Steel is purged with oxygen and argon. Smelted steel is cast into ingots weighing up to 18.6 tons , which are used for the production of sheet metal.
Shop hot rolling thin sheet produces hot-rolled steel sheets and coils in thicknesses from 2.0 to 8.0 mm. Shop hot rolling thin sheet equipped units to ensure supply of rolled sheets and coils. Continuous sheet mill ” 1680 ” with a maximum production capacity of 3.7 million tons per year is intended for the production of hot-rolled strip thickness 2.0-8.0 mm, width 860-1500 mm, weighing up to 16 tons roll on three -forming units produced more 500 sizes of cold-formed profiles of carbon and low-alloyed steel with a thickness of 1.0 to 8.0 mm and the width of the scan profile to 1440 mm.
Cold rolling shop number 1 produces cold- rolled flat products in thicknesses from 0.5 to 2.0 mm , width from 850 to 1500 mm in sheets up to 4000 mm in coils weighing up to 16 tons, as well as cold strip thickness from 0.2 to 2.0 mm.
In CHU number 1 on a continuous chetyrehkletevom mill “1680 “, two single-stand reversing mills ” 1680 ” and ” 1200 ” and two continuous narrowband chetyrehkletevyh mills , dvadtsativalkovom mill “1700” and two continuous narrowband chetyrehkletevyh mills “450” ??and “650” produced cold rolled carbon and low alloy steel. Shop is equipped with facilities for training , cross-cutting and slitting , ensuring the supply of cold-rolled steel with a thickness of 0.2 to 2.0 mm, width from 10 mm to 1500 mm and a length of 3950 mm to sheet and coils weighing up to 15 tons
Cold rolling shop number 3 on the mill ” 2800 ” produces cold-rolled sheet with a thickness of 1.5 to 5.0 mm, a width of 1000-2300 mm and lengths up to 3500 mm of carbon steel. The shop has a specialized department for the production of ground and polished sheets and coils. Maximum production capacity for hot-rolled – up to 3.7 million tons, cold-rolled steel – 1.1 million tons, cold-formed profiles – up to 500 thousand tons.
INTEGRATED MANAGEMENT SYSTEM
Zaporizhstal has an Integrated Management System for Quality, Energy Efficiency, Labour Protection and Environment (ISM), which meets the requirements of international standards ISO 9001, ISO 14001, ISO 45001 and ISO 50001.
Certificates of compliance with international standards confirm the achievement of real and sustainable improvements of the plant, as a manufacturer of sinter, cast iron, steel slabs made of carbon, low-alloy and alloy steels, hot-rolled and cold-rolled steel in coils and sheets, steel strips, formed sections, tin plates, oxygen, nitrogen and inert gases. The integrated management system of PJSC “Zaporizhstal” focuses on the demands and expectations of consumers, staff, society, authorities and seeks to increase long-term competitiveness.
Priorities in this area are the production of high quality products while ensuring safe working conditions for staff, minimizing environmental impacts, protecting health of the population who live in the region of the plant and improving energy efficiency.
CORPORATE ETHICS AND COMPLIANCE
Metinvest’s Code of Ethics has guided ethical business conduct within the Group since 2013. It emphasises core values like human rights, professionalism, leadership and diversity. Employees can anonymously report any violations of their rights through the Trust Line.
MANAGEMENT
TARAS SHEVCHENKO
Acting General Director of Zaporizhstal
Taras Shevchenko began his work career at the Dnipropetrovsk Metallurgical Plant named after Petrovsky, where he worked his way up from an assistant of mill operator to chief engineer – first deputy general director.
From 2000 to 2002, Taras Shevchenko served as the chief engineer of the Alchevsk Iron and Steel Works. In 2002, he held the position of General Director of the enterprise.
In 2017, Mr. Shevchenko led the Ilyich Iron and Steel Works in Mariupol, and under his leadership, strategic projects for the environmental modernization of the enterprise were implemented. Since 2022, he has been managing the Repair Department of the Operational Directorate of the Metinvest Group, where he has built an effective management system for the engineering function.
In August 2024, Mr. Shevchenko was appointed Acting General Director of Zaporizhstal.
Taras Shevchenko graduated from Dnipropetrovsk Industrial College with a degree in Electrical Engineering and from Dnipropetrovsk Metallurgical Institute with a degree in Metal Working Processes.
His significant professional achievements and personal contributions to the development of Ukrainian metallurgy have been recognized with the title of Hero of Ukraine. In addition, Taras Shevchenko has the title of “Honored Metallurgist of Ukraine” and the Order of Merit, 3rd Class.