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Siemens to Replace Open-Hearth, Ingot-Based Steelmaking Plant for Zaporizhstal, Ukraine
09/29/2008 - Siemens VAI Metals Technologies will supply a complete steelworks for Ukrainian steel producer Zaporizhstal Integrated Iron & Steel Works JSC, including desulphurization stations, LD steelmaking converters, ladle furnaces, VOD plant, dedusting facilities and slab casters.
The Ukrainian steel producer Zaporizhstal Integrated Iron & Steel Works JSC (Zaporizhstal JSC) awarded Siemens VAI Metals Technologies a major contract for the supply of hot-metal desulphurization stations, LD steelmaking converters, ladle furnaces, a vacuum oxygen decarburization plant, dedusting facilities and slab casters for a new steel mill under construction in Zaporizhzhya, a city in southeastern Ukraine.
This metallurgical complex will be capable of producing 4.7 million tonnes of carbon steel grades per year for a wide range of industrial applications. Following start-up of the oxygen steelmaking facilities scheduled to begin in late 2010, Zaporizhstal JSC will eventually terminate its open-hearth-steelmaking production and ingot-casting route, resulting in significant cost savings, product quality and environmental advantages.
Siemens VAI will provide basic engineering for the new facility’s steel bay, as well as plant layout, detailed engineering, and the supply of key process equipment. This includes two hot-metal desulphurization stations, two 250-tonne-capacity LD (BOF) oxygen steelmaking converters, two twin-station ladle furnaces, a VOD (vacuum oxygen decarburization) plant, two twin-strand slab casters, primary and secondary dedusting facilities, and the related electrical and Level 1 and Level 2 automation systems. Siemens VAI will also supply two hot-metal ladle-transport lines, twelve 300-tonne torpedo cars for transporting hot metal, ladles, a laboratory, and various auxiliary facilities and spare parts.
The LD converters will be outfitted with the VAI-Con Link suspension system, oxygen lance systems, sublances and VAI-Con slag stoppers to minimize slag carry-over during tapping. Converter doghouses will help to reduce converter emissions within the steel bay and improve operational safety. The dry-type primary dedusting systems will be supplied with round-type electrostatic filters characterized by a low energy consumption and high degree of efficiency. The offgas cooling stack will be designed as a waste-heat boiler for the generation of steam. Siemens VAI will also supply a gas-recovery system and secondary-dedusting systems, the latter of which will be equipped with pulse-jet filter technology.
The two 2-strand slab casters with straight molds are bow-type casters with bow radii of eight meters and maximum metallurgical lengths of 27.8 meters. The machines will be capable of casting a total of 4.7 million tonnes of slabs per year at thicknesses of 150, 165 and 220 millimeters and in widths between 900 and 1550 millimeters. Technological packages will be include LevCon automatic mold-level control with fully automatic start of casting operations; MoldExpert for prevention of strand breakout; DynaWidth for automatic adjustment of the slab width during casting; and DynaFlex for the on-line adjustment of the mold-oscillation parameters. Siemens VAI will also install SmartSegments for remote adjustment of the roller gap settings for casting different slab thicknesses; together with DynaGap SoftReduction technology, they will compress slab thickness in the area of final strand solidification to improve the internal slab quality. Level 2 process models include the Dynacs secondary cooling model, YieldExpert for optimization of the cut-slab length as well a VAIQ slab-quality control.
Siemens VAI’s scope of supply will also include advisory services for erection, start-up and commissioning as well as training.
Zaporizhstal JSC is one of the largest industrial enterprises in the Ukraine. In the year 2007, the company produced approximately 4.5 million tonnes of crude steel comprising carbon, low-alloyed, alloyed and stainless steel grades. The company's products are sold to some 100 countries worldwide and are used by welded-tube producers, for domestic appliances and in the automotive, machine-building, agricultural and transportation industries.
VAI-Con, Dynacs, SmartSegment and DynaGap SoftReduction are registered trademarks of Siemens AG in certain countries.
The Siemens Industry Sector (Erlangen, Germany) is a leading international supplier of production, transportation and building systems. The Sector comprises six Divisions: Building Technologies, Industry Automation, Industry Solutions, Mobility, Drive Technologies and Osram. In fiscal 2007 (ended September 30), Siemens Industry generated sales of approximately EUR40 billion (pro forma, unconsolidated) with around 209,000 employees worldwide.
With the business activities of Siemens VAI Metal Technologies, (Linz, Austria), Siemens Water Technologies (Warrendale, Pa.), and Industry Technologies (Erlangen, Germany), the Siemens Industry Solutions Division (Erlangen, Germany) is one of the world's leading solution and service providers for industrial and infrastructure facilities. Using its own products, systems and process technologies, Industry Solutions develops and builds plants for end customers, commissions them and provides support during their entire life cycle.
With the business activities of Siemens VAI Metal Technologies, (Linz, Austria), Siemens Water Technologies (Warrendale, Pa.), and Industry Technologies (Erlangen, Germany), the Siemens Industry Solutions Division (Erlangen, Germany) is one of the world's leading solution and service providers for industrial and infrastructure facilities. Using its own products, systems and process technologies, Industry Solutions develops and builds plants for end customers, commissions them and provides support during their entire life cycle.
