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NLMK Generates Significant Savings through PCI Implementation at Novolipetsk
02/26/2015 - Russia’s NLMK Group made a saving of 425 million rubles in 2014 through the use of pulverized coal injection (PCI) technology at two blast furnaces at its Novolipetsk production site in Lipetsk.
PCI technology involves the co-injection of natural gas and fine thermal coal particles into the blast furnace resulting in lower natural gas and coke consumption. Replacing the expensive feedstock, i.e. natural gas and coke with the cheaper alternative, i.e. steam coal, reduces the cost of pig iron production; and subsequently that of steel manufacturing; while maintaining high quality and efficiency.
NLMK demonstrated its commitment to bringing innovative technological solutions to Russia when it began implementing the resource-saving PCI technology at the Lipetsk site in 2013. To date, the plant has successfully completed guarantee tests and moved on to commercial operation of PCI systems at two blast furnaces: No.5 (with a capacity of 3 million tonnes per year) and No.4 (with a capacity of 2 million tonnes per year).
Even during the PCI testing period coke consumption at these blast furnaces decreased by 10% and natural gas consumption decreased by 40%.
Sergey Filatov, Novolipetsk managing director, said: “More than a third of Novolipetsk blast furnaces have been fitted with PCI systems. We continue to work on enhancing the efficiency and cutting the cost of pig iron production. With this in mind, we plan to equip almost all Novolipetsk blast furnaces (which produce over 12 million tonnes of pig iron per year) with PCI systems. We are currently preparing to implement this technology at the plant’s two largest blast furnaces: No.6 (with a capacity of 3.2 million tonnes per year) and No.7 (with a capacity of 4.2 million tonnes per year). As a result, coke consumption at these furnaces will reduce by 20%, and natural gas consumption will reduce by 60%.”
Productivity of all blast furnaces in 2014 was increased as a result of improved pig iron smelting technology; mastering pulverized coal injection; and increased operational efficiency. Daily output increased by 2.3% year-on-year to reach an average of 36,000 tonnes of pig iron. The average daily production of Blast Furnace #7, the most modern blast furnace in Russia, increased by 15.1% to 11,900 tonnes per day.
NLMK demonstrated its commitment to bringing innovative technological solutions to Russia when it began implementing the resource-saving PCI technology at the Lipetsk site in 2013. To date, the plant has successfully completed guarantee tests and moved on to commercial operation of PCI systems at two blast furnaces: No.5 (with a capacity of 3 million tonnes per year) and No.4 (with a capacity of 2 million tonnes per year).
Even during the PCI testing period coke consumption at these blast furnaces decreased by 10% and natural gas consumption decreased by 40%.
Sergey Filatov, Novolipetsk managing director, said: “More than a third of Novolipetsk blast furnaces have been fitted with PCI systems. We continue to work on enhancing the efficiency and cutting the cost of pig iron production. With this in mind, we plan to equip almost all Novolipetsk blast furnaces (which produce over 12 million tonnes of pig iron per year) with PCI systems. We are currently preparing to implement this technology at the plant’s two largest blast furnaces: No.6 (with a capacity of 3.2 million tonnes per year) and No.7 (with a capacity of 4.2 million tonnes per year). As a result, coke consumption at these furnaces will reduce by 20%, and natural gas consumption will reduce by 60%.”
Productivity of all blast furnaces in 2014 was increased as a result of improved pig iron smelting technology; mastering pulverized coal injection; and increased operational efficiency. Daily output increased by 2.3% year-on-year to reach an average of 36,000 tonnes of pig iron. The average daily production of Blast Furnace #7, the most modern blast furnace in Russia, increased by 15.1% to 11,900 tonnes per day.
