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Siemens Replaces, Restarts Nizhny Tagil BOF Converter in 75 Days
12/19/2007 - Siemens Metals Technologies replaces and starts up a BOF converter and its offgas-treatment system for Russian steel producer Nizhny Tagil Iron & Steel Works, the first of four BOF converters it will replace for the company by 2009.
Siemens Metals Technologies replaced and started up a BOF converter and its offgas-treatment system for Russian steel producer Nizhny Tagil Iron & Steel Works within a quick, 75-day turnaround—15 days less than the time period stipulated by the contract.
The converter replacement was part of a major modernization program, within which Siemens will replace three more BOF converters, including the environmental facilities, by 2009. According to Siemens, this project’s quick turnaround was achieved through meticulous engineering planning and intensive on-site activities carried out seven days per week. All converter replacement work was implemented with minimal interference to ongoing steelmaking operations.
Following start-up of the first 160-tonne-capacity replacement converter in November 2007, more than 20,000 tonnes of steel in 128 heats were tapped during the first eight days, with dust-emission requirements met. Siemens will replace the second converter in March/June 2008, the third in the fourth quarter of 2008, and the remaining No. 4 Converter in 2009.
The converters are equipped with bottom stirring, automatic slag stopper, oxygen lances with flow rate 500 m3/min. With a larger converter size and shorter tap-to-tap times the annual steel output of each converter will be increased from approximately 900,000 tons to 1.1 million tons. At the same time, the cost-effectiveness, environmental emissions, onsite working conditions and steel quality will be improved.
Siemens Metals Technologies’ project scope for each BOF converter replacement includes engineering and equipment supply, installation of the new converters, electrics and basic automation, and replacement of the outdated off-gas treatment system. Siemens will also make modifications to the low-bunker system, and install a new feeding line for converter and ladle charging.
The major challenge of this project is that all onsite installation work is to be performed during full steel-production operations and within a very tight timeline of less than three months for each converter replacement.
Nizhny Tagil Iron & Steel Works (NTMK) is part of the Evraz Group SA, one of the largest Russian metals producers. In 2006, NTMK produced approximately 3.6 million tons of steel in their converter steel mill, which was further processed to semi-finished products such as slabs for external sales and long products for various applications, in particular, railway products.
Metals Technologies (MT), a Division of the Siemens Industrial Solutions and Services Group (I&S), is one of the world’s leading engineering and plant-building companies for the iron and steel industry as well as for the flat-rolling sector of the aluminum industry and for open-cast mining. MT, which was created from the integration of Voest-Alpine Industrieanlagenbau, Linz, Austria, and the electrical engineering product business and automation solutions of Siemens, provides a comprehensive range of supplies and services for all related technological processes and integrated automation solutions for the entire life-cycle of metallurgical plants.
The Siemens Industrial Solutions and Services Group (I&S) is the integrator of systems and solutions for industrial and infrastructure facilities and global service provider for the plant and projects business covering planning, installation, operation and the entire life cycle. I&S uses its own products and systems and process technologies in order to enhance productivity and improve competitiveness of companies in the sectors of metallurgy, water treatment, pulp and paper, oil and gas, marine engineering, open-cast mining, airport logistics, postal automation, intelligent traffic systems and industrial services. In fiscal 2007 (to September 30) I&S employed a total of 37,000 people worldwide and achieved total sales of EUR 8.894 billion, according to U.S. GAAP.
