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Enlightment season proceeds: TOREX delegate submits a paper at the VI International Forum "Seymartec Mining. An efficiency of mining industry - 2022"

An annual forum took place in Chelyabinsk town during June 27-29, gathering more than 400 delegates, 150 speakers and 15 countries in total. As a part of forum agenda, TOREX had drafted a presentation dedicated to contemporary issues in the pelletizing industry of Russia, focusing on environmental impact, quality of a feedstock and equipment topics. An audience of the forum encompassed some representatives of industrial facilities, vendors, among those are distinguished companies of metallurgical sector and long-term associates of TOREX. In addition to active involvement, our company delegate acquired a valuable up to date insights in the automation and digitalization of ore mining and concentrating plants, as well as improvement methods of beneficiation process.

The major metallurgical event was being held through June 2-3 in Tula town and gathered the leading experts of an industry, namely Evraz, Metalloinvest, Mechel, MMK, NLMK, Severstal, OMK, TMK, PMH. The summit speakers enlightened an audience on the up to date state of metallurgical sector, including the promising trends of development and approaches which could facilitate the existing facilities to sustain under constrained market conditions. One of the top issues on the summit agenda was an eco-friendly transformation of production in the ferrous metallurgy of Russia along with operation of metallurgical enterprises facing a decarbonization challenges and the best ESG techniques in use.  Besides, the summit delegates were invited to visit the workshops of "Tula-Steel" LLC which is prominent in its import substitution products and adds a tangible contribution to development of domestic metalware industry. 

In the realm of sci-tech services rendered by TOREX company at OEMK steel plant, a few basic scenarios are envisaged to ramp up a production rate by 600 thousand tonnes of fired pellets per annum. In essence, the proposed technical solutions will lead to further boosting of capacity up to 900 thousand tonnes of oxidized pellets to be consumed by metallization plants No 3 and 4 previously revamped. Minimized OPEX goes as an extra accomplishment. In parallel, improvement of the automatic process control system is ongoing as per TOREX technical specification. As of now, revamping project has reached the stage of process equipment erection, including its biggest unit – drum pelletizer (110 tonnes). In total, over 35 items of mechanisms and equipment are about to be mounted. Start up and commissioning of the technological complex is scheduled for 4th quarter of 2022 with over 2 billion rubles invested by Metalloinvest Group of Companies.

Over the October and December 2021, TOREX experts performed the enhancements of DeSOx pilot plant operating modes at the industrial facility of “Karelsky Okatysh”JSC. Fine-tuning has been carried out under wide range of air-gas flow parameters amid production of the versatile types of pellets and application of calcium-hydrated lime as a chemical agent. Thereon, the results and protocols of measurements as to pollutant concentrations in the emissions are studied at the laboratory of pilot processing plant “Gor-Mash-YuL” in Kostomuksha town. These results appear to be encouraging and reveal that a high desulfurization rate up to 98,0% is attained by TOREX team research equipment while a concentration of sulfur dioxide at the outlet of the pilot plant is less than 50 mg/nm3. Presently, the research activities are ongoing with regard to representative samples of desulfurization sludge in order to obtain an environmentally friendly and commercial by-product.

For all TOREX employees 2021 is encouraged by a landmark award-winning event to be proud of  - the second Russian Federation Government Prize in science and engineering. The award is granted for successful feasibility of the major Russian project in ferrous metallurgy: "Development and implementation of an innovative energy-efficient and environmentally friendly pelletizing plant producing a high-quality iron ore pellets", which is "Mikhailovsky GOK" PJSC owned by Metalloinvest Group of companies. The emphasis of award is in recognition of proficiency of the Russian metallurgical science alongside with practical experience in heat engineering accumulated by NPVP TOREX personnel for decades. The solid ground of contemporary pelletizing technology is pioneered by founders of our company who became the mentors for present skillful engineers, preserving the Soviet legacy of heat engineering expertise applicable to a metallurgical production. Among those are honorable and leading scientists and engineers, namely Abzalov V.M., Maizel G.M., Evstyugin S.N., Klein V.I., Bokovikov B.A. For over 20 years they have been showing an abundant dedication and striving to improve and apply the unique techniques in upgrading of brownfield projects in numerous CIS countries, meanwhile nourishing a new generation of experts. 

The Prize diploma was officially presented in the House of Government, Moscow, on December 16 by Prime-Minister of Russia - Mikhail Mishustin.

From March through July 2021 the previously designed pilot desulfurization plant has been erected and commissioned  by "NPVP TOREX" LLC team at the production facility of "Karelsky Okatysh" JSC. Practically, a feasibility of the plant is accomplished, whereby an efficiency of SO2 removal rate is up to 80%, which is followed by sludge sampling to predetermine its chemical composition and consumer properties. Further activities on the pilot plant involve a fine-tuning of operating mode so as to to attain the target figures of desulfurization along with representative sampling. In the realm of TOREX commitment to environment, these steps will lead to the development of zero waste recycling technology.     

The wide range of process solutions developed by TOREX team as to retrofitting of the indurating machine MOK-592 led to a core target achievement - production of the high quality material and fired pellets at all process stages. These materials to be used for onward blast furnace smelting and DRI processes (whereby a strength is 280 kg/pellet and FeO content is lower than 0,5 %) with lower consumption of energy resources (e.g. consumption of natural gas is  below 10 m3/t, power consumption within entire technological complex is lower than 36 KW·h/t) with a min negative environmental impact. In this case, a total ramp up of production rate in reference to design values has been increased by 10%. The named project solutions result in significant expansion of pellet product list at the "Mikhailovsky GOK after A.V. Varicheva" PJSC along with improvement of consumer properties of pellets. 

 

To minimize the emissions of sulfur dioxide, TOREX experts jointly with academicians of Urals Federal University elaborated the wet desulfurization technology to clean the flue gases discharged from indurating machine with application of ground limestone as a chemical agent.  The project scope of works comprise the required technological calculations, development of technical documentation and simulation of pilot plant along with manufacturing and procurement of its key equipment components, research of desulfurization by-products (sludge, flue gas, water). The pilot plant is designed to simulate the technological procedures of flue gas treatment under various parameters (temperature, pressure, content of SO2) and during production of versatile types of material.  The target is to verify the equipment under actual operating conditions and to prove an efficiency of selected desulfurization technology.

TOREX company has presented the state-of-the-art technology under its trade name NextGen Pelletizing© to the global iron ore industry, in reliance on viable operation of the new generation indurating machine in Russia. To improve a power efficiency of the NextGen Pelletizing© technology, Tek7 engineers have employed CFD, FEA and other simulation methods. This novel approach to design philosophy along with advantageous thermal circuit developed by TOREX ensure a max efficacy and customization of individual elements of the indurating machine tailored to specific targets and conditions of a Client.     

 

The optimisation system has been mounted and commissioned in-situ by TOREX engineering team. Consequently, the following activities are implemented: an adjustment of the sensors, comparing of measured dimensions with the results of laboratory screen sizing along with selection of sensor installation points above the pelletizing disks. As a whole, integration of the Granulometer system is meant to ensure a performance improvement of the indurating machines, as well as reduction of the gas and energy consumption under operating conditions of Lebedinsky GOK.