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Advantages of key TOREX process solutions indicate our competitive edge.
NPVP TOREX has developed a comprehensive approach to solve the various process tasks and challenges. This approach envisages an optimization of the induration technology and temperature-and-filtration modes of heat treatment of the pellet bed with various application fields (blast furnace or DRI). It also comprises the process issues as to optimization of composition for pellet mixed material, and its formation technology during pelletizing process. The structural characteristics and thermal-physical properties are also part of said approach.
TOREX comprehensive approach
Initially, the comprehensive approach has been used by TOREX during retrofitting of the exisitng indurating machines of Lebedinsky GOK in 1998-2001. After two successful stages of retrofitting, a specific production rate of indurating machines ramped up by 25 % with reduction of the natural gas by 32% while producing the blast furnace pellets.
The same comprehensive approach was used during retrofitting of the indurating machines OK-520 of the Mikhailovsky GOK. Consequently, more outstanding results have been attained. First of all, two indurating machines OK-1-520 of Mikhailovsky GOK have produced up to 10 mtpa of pellets due to the first retrofitting phase. For comparison, three identical indurating machines (without retrofitting) were producing only 9 mtpa. The estimated economic benefit from the first phase of retrofitting at Mikhailovsky GOK accounts for 1.5 billion rubles per annum.
TOREX company is continuously dedicated to improve an efficiency and approaches to the pellet production. For instance, we have designed the 4th generation straight grate indurating machine (MOK-1-592) with a max efficiency in power and production rates compared with the modern analogies in the world.
Intensive heat exchange and gas-dynamic processes within IM with a certain area create optimal conditions to attain a high production rate and low fuel and power costs. Minimized atmospheric emissions is one more valuable accomplishment.
TOREX concept of the designed pallet car installed at the induration machine of Mikhailovsky GOK (Russia)
TOREX design solution on the retrofitting of gas duct system (indurating machine No 4) at Lebedinsky GOK (Russia), including the new direct recuperator, its new frame and gas duct arrangement.
The key state-of-the-art solutions applicable to the brand-new designed indurating machine:
A standard approach used by indurating machine manufacturers is to improve a reliable design of the indurating machine and accessory equipment. TOREX is primarily focused on improvement of a core process. Thus, the first priority is to meet the process requirements. The second one is manufacturing features and commitment to standard design of the various units.
MOK-1-592 is an indurating machine of the new generation, with a very high degree of automation of the various process operations and heat treatment allowing for lowering considerably the power & utilities consumption and harmful emissions to the ambience, this machine is second to none at this point.
The basic features of a flexible thermal diagram of the new indurating machine:
- Thermal diagram can be adjusted to produce the pellets of different type (magnetite or hematite) and designation (BF or DRI pellets).
- Flexible diagram of the drying zone comprises the three sections with various length and temperature of the heat carrier. It facilitates an operation with pellets of different moisture, grain-size and tangible composition.
- It becomes more common to prepare the special requirements for relatively small batches of the fired pellets. An increased strength was ensured by means of flexible thermal diagram
- Fan-less gas recycling mains (2 collecting mains/manifolds)
- Gas ducts and collecting mains/manifolds ensuring minimum
- No dedusting of gases in recycled gas ducts
- Rational proportioning of loads on process fans (maximum
- Flexibility of in-furnace thermal and gas flow mode
Need to reduce NOx and other hazardous emissions?
TOREX provides an environmental friendliness and efficiency in one package