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.
After a technical meeting held by both Parties in Milan head office of Redecam, TOREX specialists have been invited to observe the waste-to-energy plant located in Germany (Neuwied town) with an embedded desulfurization system. Afterwards, Redecam arranged a familiarization visit for the said team to its own manufacturing facility in Italy. As a result, the new data were acquired as to advanced flue gas treatment solutions and possibilities evaluated to use them at the Russian plants.
Severstal company sponsored and hosted the 4th International Scientific and Technical Conference in Cherepovets city, dedicated to scientific and technical advance within the ferrous metallurgy sector. The delegate and speaker from TOREX prepared the paper which covered one of the following agenda topics:
- Coking, agglomeration and blast furnace process
- Piping and rolling
- Industry 4.0
Being a long-time partner and process consultant of Mikhailovsky GOK for the last decades, TOREX initiated an implementation of the target research and development activities focusing on the joint lab, pilot-scale tests and full-scale tests of process modes for a production of magnesian pellets. Those works comprise the development of new compositions, pelletizing and induration modes, determination of metallurgical properties, and predictive modeling of blast furnace values.
As the long-term collaboration with Lebedinsky GOK continues, TOREX commenced the activities on adoption of the energy-saving diagram elements. As a result, the Contract has been signed with TOREX as to process design supervision along with elaboration of a process procedure for retrofitting of indurating machine no. 4. Upon completion of design, the comprehensive erection activities are scheduled by our engineers at the retrofitting facility.