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Diagram of Cast Iron and Steel Making Process

Схема металлургического производства

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Iron and Steel Making Process

Alchevsk Iron & Steel Works, PJSC is one of the largest manufacturers of the metal products in Ukraine. At the present moment 6 major types of products are manufactured at metallurgical facilities. Metallurgical production of PJSC «Alchevsk Iron & Steel Works» consists of sinter, blast-furnace, steel-making and rolling facilities. Modern high-performance equipment, effective technologies, qualified workers of the Works – all these factors help to produce and to deliver the products in accordance with requirements of international and state standards.

Production of Sinter and Iron

Sintering plant. Designed performance of sintering plant amounts 5 400 000 t/year or up to 15 000 t/day. It is designed for production of sinter which is used as high-quality raw material for iron casting from mixtures of iron-ore concentrates, sintering ores, and ferrous additions in blast-furnaces (scale, blast-furnace dust, sludge, etc.).

Sintering plant includes 6 sinter machines with total agglomeration area of 504 m2.

Blast furnace plant. Designed performance of blast furnace plant amounts 5 320 000 t/year. Blast furnace plant produces pig iron for steelmaking, cast iron for casting at casting machines and synthetic iron for foundry. Own-produced sinter, imported iron-ore pellets and iron ore are used as feed stock. At the present moment blast furnace plant includes 4 blast furnaces:
  • BF №1 – effective volume 3000 м3;
  • BF №3 – effective volume 1386 м3;
  • BF №4 – effective volume 1386 м3;
  • BF №5 – effective volume 1719 м3.

Operation of all blast furnaces is based on technology of iron-making with pulverized coal blowing under combined blasting.

Steel making

Oxygen converter shop. Production performance of the plant amounts 5 472 300 t of steel per year. Liquid steel smelting is performed through LD-process at oxygen converters of combined blowing. Rated capacity of every converter amounts 300 t, which provides high performance of steel making process. Two two-position secondary desulfurization units are installed at charging aisle of the plant to maintain specified sulfur content in liquid pig iron delivered form the blast furnace plant. Two double-strand continuous-casting slab machines together with two-position ladle-furnace unit and degassing unit provide secondary treatment and liquid steel casting into slabs 200 – 300 mm in thickness, 1000 – 1800 mm in width, 3600 – 12000 mm in length. Upstream casting into moulds can also be applied if required.

Oxygen converter shop equipment as well as applied technology complies with higher modern standards in field of steelmaking production, which allows to perform smelting and casting of over 100 grades of steel including skelp grades.

Both semi-finished blanks for rolling mills of the works and finished products for external customers are manufactured at Oxygen converter shop.

For continuous improvement of production process and modernization of equipment the works cooperates with scientific and research and design institutions.

Rolling

Rolling facilities of the works are represented by blooming-slabing 1250, plate rolling shops 2250 and 3000, and semi-continuous heavy section shop 600.

Blooming mill. Performance capacity amounts 2 000 000 t/year. This shop is designated for blanks (slabs) production to satisfy needs of plate mills № 1 and № 2, and blooms production for section rolling mill. Blooms, axial and forging blanks from 250x250 to 400x400 mm in section and slabs from 590 to 1250 mm in width, from 110 to 320 mm in thickness and from 1200 to 6000 mm in length are rolled at 1250 blooming mill.

Plate mill № 1. Plate mill № 1 is equipped with mill 2250 with subsequent arrangement of two stands. Achieved production capacity amounts 464 000 t/year. The shop produces plates of carbon, low-alloy, and structural steels from 4 to 25 mm in thickness, 1219 – 2000 mm in width and up to 12000 mm in total length for finished plate. Continuous cast slabs from Oxygen converter shop and rolled slabs from blooming meel. After rolling rolls are corrected, edges are cut at circular shears; plates of specified length are cut at guillotine shears and then sampling for tests is performed.

Plate mill № 2. Plate mill № 2 is equipped with mill 3000, having production capacity of 1 200 000 t/year .

Shop with subsequent arrangement of two stands produces plates from 6 to 50 mm in thickness, 1219 – 2650 mm in width and up to 12000 mm in total length. Shop is equipped with thermal separation department and unit of controlled cooling of the workpieces (UKO). Continuous-casted slabs delivered from Oxygen converter shop and rolled slabs delivered from blooming mill are the source blankets for rolling of all plates.

Basic range of products manufactured at plate mills (Plate mill № 1, Plate mill № 2) is represented by plates of shipbuilding, boiler, bridge, structural, alloy and low-alloy steels; skelps (strength category K 52 – K 60) manufactured according to technical specifications and technical agreements.

Plates quality is additionally controlled at ultrasound units.

Section shop. The shop is equipped with mill 600 having designed capacity of 1 655 000 t/year designated for rolling of sections and bars. Blooms with cross-section of 265х265 mm, 300х300 mm, 310х310 mm, 318х318 mm and length of 3250-6000 mm serve as source blanks. Heavy sections are manufactured at semi-continuous mill 600 from carbon, alloy and low-alloy steel, and also rods and square billets:
  • steel skelp;
  • mine working supports SVP №№17 - 33;
  • steel equal-flanges angles №№ 10; 11; 12,5;
  • channels with parallel flange edges №№ 12 - 24;
  • channels with inclined flange edges: С8"; С10";
  • double T-shapes with inclined flange edges №№ 14 - 20, W8;
  • double T-shapes with parallel flange edges: I 120, I 140;
  • rods ØØ 70 - 150 mm;
  • square billets 100, 120, 125 mm.

Appliance of the practice of mine supports manufacturing from alloy steel provides significant increase of reliability and capability of the goods.

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