In response to the rising costs of natural gas and the need for energy efficiency, the introduction of energy-saving technologies, such as PCI (Pulverized Coal Injection), is crucial for modernizing blast furnace production. The construction of a PCI complex at Zaporizhstal JSC marks a significant step towards enhancing production processes while reducing operational costs.
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 the harmful influence that the cost increase of energy resources had on the economy of enterprises, particularly, the increase in the 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 its large size and imperfection. Introduction of cheap and caloric natural gas in the blast furnace production completely sidelined this idea. When the cost of natural gas skyrocketed, the viability of PCI installations was reassessed. At that time, 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 for introduction at Zaporizhstal JSC greatly differs from the previous constructions, allowing for the injection of up to 200 kg of coal dust per one ton of pig iron. This installation is designed for the production of 4.5 million tons of pig iron per year. Such an amount is required to meet the capacities of the Works’ converter production.
The economic effect of introducing the new installation is expected to reach the level of 200-266 million UAH. This will allow for the recovery of expenditures on its construction within 1.5-1.8 years of its operation.
PCI will enable a complete withdrawal from the usage of process natural gas and will significantly maintain a considerable economy of coke. This means that the prime cost of pig iron production will be reduced.
Works on designing the complex started in 2007. Construction began in 2008. Despite the challenging economic period, construction is proceeding 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 the firm “Kuettner”. The PCI complex consists of several separate units interconnected with one another.
- At present, all the main processing equipment under the contract with the firm “Kuettner” has been delivered to the Works, including 2 mills for grinding coal, ventilators for process and hot blast stove gas, as well as equipment for blast furnace distribution devices, — said V.B. Shalayev, the supervisor of the construction works from the Department for Capital Construction.
- The general subcontractor “SMU Zaporozhstalstroy-1” JSC in 2008 accomplished jobs on the installation of pile grids for the coal preparation department made of assembly-reinforced piles, and all the foundations for the frame and processing equipment. More than 1300 tons of metal structures have been assembled, and the erection of two mills and two ventilators in ventilation room No.2 has started. The bin trestle pile grids and bored piles have been completely installed, with 90% of the foundations for the frame completed, and 1206 tons of metal structures for the trestle and bins frame have been assembled. Works on the energy trestle with dust delivery pipelines to the distributing devices of blast furnaces have been fulfilled by 50%. Jobs on mounting metal structures and walls made of sandwich panels of the distributing devices of blast furnaces Nos. 2, 3, 4, and 5 have been entirely accomplished. The main construction jobs on the nitrogen compressor station have been carried out.
In 2009, a task was set to finish works on the main technological cycle and complete construction in the third quarter.
I would like to commend the good work of the Chief Mechanic Department shops who manufactured the metal structures and nonstandard equipment. Deputy Chief Mechanic A.V. Dzyuba is overseeing the construction works.
The work group on the construction of the PCI complex is led by A.P. Fomenko, the chief specialist on steel and iron production. One of the group's main tasks is coordinating the actions of the erection workers of SMU and specialists from the firm “Kuettner”.
Unfortunately, due to financial problems, questions concerning the delivery of materials, items, and structures are not resolved in a timely manner. However, the staff of the Logistics Department is doing its utmost to meet the needs of the construction site by supplying it with material resources.
The management of the Works prioritizes the timely commissioning of the PCI complex. Therefore, it demands from all participants of the construction work not to reduce the pace of construction and to fulfill the set tasks.