Displaying items by tag: Upgrade

UK: Fairport Engineering has revealed details on its work on Hanson’s 1Mt/yr Purfleet ground granulated blast furnace slag (GGBS) grinding plant. The plant includes two closed circuit ball mills and a vertical roller mill. Fairport Engineering worked on a project to improve the raw material intake facilities at the unit to replace a storage bunker with a new feed hopper and ramp. In the next phase the bunker is likely to be removed and replaced with a second feeding system.

The new system includes a reinforced concrete access ramp that will allow front-end loaders to deposit raw material into a 30t capacity Hardox lined hopper before being metered, at up to 200t/hr, by a vibrating feeder, onto an exiting conveyor belt that feeds the GGBS plant. The entire installation was completed in six weeks.

Netherlands: Ecocem Benelux has inaugurated a new 5000t export silo at its Moerdijk ground granulated blastfurnace slag (GGBS) plant. The new silo has been built at the waterfront in Moerdijk and rests on 65 piles sunk to a depth of up to 50m. The system operates via a screw extractor that conveys the GGBS to the centre of the bulk silo, where screws and a bucket elevator carry it to the new 150m³ day-silo. Both trucks and ships can be directly loaded from the silo: trucks on the weighing bridge situated under the silo and ships via a pneumatic transport installation with a maximum capacity of 250t/hr.

Ecocem Benelux is a subsidiary of Ireland’s Ecocem Materials. Ecocem Benelux supplies GGBS in bulk to the Belgium, Netherlands and Luxembourg (Benelux) market for both concrete and mortars. The facility also exports to the Swedish market. Since opening in 2002 the plant has doubled its production capacity to 0.65Mt/yr.

Turkey: Erdemir Group has ordered new INBA slag granulations systems as part of an order for two new blast furnaces (BF) from Luxembourg’s Paul Wurth for its Ereğli and Iskenderun integrated steel plants. At both sites a new furnace will replace an older production unit. The new blast furnaces are scheduled for blow-in in March 2021 and May 2021 respectively. No value for the order has been disclosed.

At Ereğli Erdemir’s new BF2 will have a hearth diameter of 10m, 24 tuyeres and two tapholes. It will produce 5000t/day of hot metal from an inner volume of 2188m³. At Isdemir the new BF1 will be sized at 12.5m in the hearth and 3587m³ of inner volume; it will be fitted with 32 tuyeres and four tapholes and will produce 7900t/day, which further increases the hot metal capacity at this site.

Paul Wurth will execute both projects on an EP basis including the supply of technological key items and related supervision of erection and commissioning. The orders include basic engineering of the blast furnaces with profile, cooling and lining concepts as well as the design of the stockhouses, top gas cleaning plants, slag granulation plants and BF cooling units.

For both furnaces, Paul Wurth will supply Bell Less Top charging systems and bleeder valves, refractories for the hot blast mains and bustle pipes, tuyere stocks with tuyere phenomena detection system (TPDS), technological and critical items for the top gas cleaning plants (consisting of axial cyclones, annular gap scrubbers) as well as for in total three INBA slag granulations systems. Extensive sets of TMT probes and process recorders include, inter alia, 3D TopScanburden surface profile meters and SOMA acoustic top gas temperature measurement. Under the same contracts, TMT will also supply fully hydraulic taphole machinery for equipping all the six tapholes in total.

Bangladesh: Confidence Cement plans to install a slag dryer unit at its plant in Madambibirhat, Bhatiary near Chittagong. The upgrade is intended to allow for uninterrupted production at its Unit-2 and Unit-3 lines, according to the Financial Express newspaper. The company also intends to demolish its 600t/day Unit-1 line due to high electricity costs and overall running costs.Confidence Cement to install slag dryer unit

Poland: Primetals Technologies has received a provisional acceptance certificate (PAC) from ArcelorMittal Poland for the replacement of the second LD (Basic Oxygen Furnace) converter at the Dąbrowa Górnicza steel works. The converter entered service in February 2018. It follows a previous project by Primetals Technologies to replace a converter at the site in 2016.

As in the case of Converter #1, Primetals Technologies supplied the vessel and the trunnion ring, including the Vaicon Link 2.0 suspension, for Converter #3. The converter bearings and the enclosure have also been renewed. The order included also removal of the existing vessel and assembly and installation of the new equipment. This had been handled by ZKS Ferrum, the Polish partner in the consortium.

ArcelorMittal Poland is the leading steel producer in Poland, operating six production plants in the south of the country. Its range of products includes profiles, rails, fittings for the construction, transport and mining industries, as well as flat products for the automotive industry and domestic appliances.

India: Wonder Cement has ordered two vertical mills from Germany’s Gebr. Pfeiffer for its Nardana plant in Rajasthan. The order includes a MVR 6000 C-6 mill for grinding slag cement and a MPS 3070 BK mill for grinding fuel. Delivery is scheduled for early 2019 and mid-2019 respectively.

The MVR mill will feature a total drive power of 5820kW. Mixed cements will be be ground to a fineness of up to 5% R 45µm. The grinding plant will be designed to process granulated blast-furnace slag with a target fineness of approximately 4500 cm²/g Blaine and blast-furnace cements with different proportions of granulated blast-furnace slag, fly ash and gypsum and different product fineness degree. Wonder Cement has requested the option to grind relatively hot clinker in the mill while at the same time being able to reduce the cement temperature, and alternatively to use cold clinker from stockpiles.

The core components such as the tension system and the grinding rollers will come from Gebr. Pfeiffer in Germany. The grinding bowl and the gearboxes for the mill and classifier will also be delivered from Europe. Gebr. Pfeiffer’s subsidiary, Gebr. Pfeiffer India, will provide the housing parts, the foundation parts and supports of the rollers as well as almost the entire high-efficiency classifier type SLS 5600 BC. Gebr. Pfeiffer India scope of supply will incorporate most of the equipment to complete the grinding plant including the plant fan.

The MPS mill will grind petcoke with a capacity of 40t/hr to a product fineness of 2% R 90µm. It will come with a SLS BK classifier, allowing both coal and petcoke to be ground in the mill, dried with process gases and then classified in the integrated classifier. Due to the high abrasiveness of Indian coal, the mill will be designed with appropriate wear protection.

Most components of the coal mill will be supplied by Gebr. Pfeiffer India. The housing and foundation parts, the grinding bowl and a large part of the power-transmitting parts will be manufactured in India. Setting up the new MPS mill is planned to coincide with the commissioning of the entire kin line.

India: Mamata Banerjee, the chief minister of West Bengal, has inaugurated JSW Cement’s plant at Salboni. The US$125m grinding plant has a production capacity of 2.4Mt/yr, according to the Press Trust of India. It started commercial production at the site in July 2017 with plans to manufacture Portland Slag Cement. The cement producer is already preparing upgrades at the unit including a US$15.6m captive power plant with a capacity of 18MW and a US$47m production capacity increase of 1.2Mt/yr.

India: KIC Metaliks plans to build a 300t/day slag cement grinding plant at its pig iron plant at Raturia in the Bardhaman district of West Bengal. The project is part of a wider upgrade at the site to turn it into a steel plant, according to Projects Today. Other upgrades a direct reduced iron kilns, a sinter plant, a rolling mill, a pulverised coal injection plant and a captive power plant. The upgrade plans are valued at around US$93m. The company is awaiting environmental clearance for the project.

Russia: NLMK Group has completed hot-testing of its new crushing and screening unit for the processing of steelmaking slag at its Lipetsk plant. The project will double the amount of scrap, or ‘metal inclusions‘, extracted from waste and returned to the production process. The new unit will process 2.4Mt/yr of slag, replacing an obsolete unit, which processed 1.7Mt/yr of slag. Metal extraction efficiency at the new unit will be as high as 95%, which will minimise the consumption of iron ore and scrap in pig iron and steelmaking operations through replacement with recoverables. The project had an investment of US$7.2m.

“The new unit will process the entire volume of our steelmaking slag, which is about 2.2Mt/yr, as well as allowing us to eliminate the need to process slag via third parties. The unit will also help us to recycle previously accumulated waste. This Strategy 2017 project is our next step towards increasing the role of recycling in bringing down steelmaking costs and reducing our environmental footprint,” said Sergei Filatov, the managing director of Novolipetsk.

Recovering production waste is one of NLMK’s priorities as part of its operational efficiency improvement efforts. NLMK Group is currently building a new briquetting plant at the Lipetsk plant. Briquettes will be manufactured from a mix of iron ore concentrate and blast furnace slag formed in the process of wet blast furnace gas cleaning. The plant will recycle more than 350,000t/yr of blast furnace waste.

India: According to local media, Sunvik Steels plans to expand its integrated steel plant in Jodidevarahalli, Tumakuru, Karnataka. The estimated cost of the project is US$86.8m.

The existing plant has three 100t/day direct reduced iron (DRI) kilns, a 12t/hr induction furnace based steel melting shop, a 100t/day roller mill, a 10MW captive power plant, a 2000bricks/day fly-ash brick plant and one 15t/day slag crusher and beneficiation plant. The proposed expansion will see the plant consist of one 200t/day DRI kiln, a 500t/day induction furnace based steel melting shop, a 500t/day roller mill, 5MW and 10MW captive power plants, a 300t/day blast furnace, two 100t/day tunnel kilns, a 2000t/day iron ore pelletisation and beneficiation, a 6000bricks/day fly-ash brick plant, a 100t/day fly-ash beneficiation plant and a 30t/day slag crusher and beneficiation plant. The project is waiting for environmental clearance.