OREANDA-NEWS. March 24, 2010. For the first time in the history of Ukrainian industry JSC Yenakiievo Metallurgical Works, part of Metinvest Group, commenced installation of the bell-less charging device (BCD) for new Blast Furnace #3.

The BCD enables reducing coke consumption rate by 10-15 kg/t of cast iron, and energy consumption by 10% along with 3-5% productivity increase. Cost of the BCD implementation is around UAH 40 mln. Construction of the new blast furnace is performed within the framework of the long-term EMZ production facilities reconstruction and upgrade program.

The bell-less charging device from Paul Vurt Company is the most advanced one-tracttray-type charging device in the world. According to the estimates of the leading world specialists, this equipment is of the next, the third generation, the innovation in blast furnace charging technologies.

When the BCD is used, furnace charge becomes more even, desired pattern of charge is attained, gas utilization efficiency improves significantly. Coke consumption rate drops by 10-15 kg/t of cast iron, blast furnace productivity improves by 3-5%.

Design of the BCD allows using of hot sinter in the charge in place of cold sinter. In combination with the closed cooling system, this enables cutting energy consumption by 10%. The dust suppression and aspiration systems of the intake funnel of the BCD allow minimizing dust emissions in the process of charging the furnace. The hydraulic system and the automated charging process control system assure safety and comfortable working conditions for the personnel. As a whole, the project has been certified as compliant with the international OHSAS 18001:2007 industrial safety standard.

The bell-less charging unit will include one tract device with a weighing bunker of 24 m3, distributing trough of 3.5 m, primary pressure equalizing assembly using semirefined blast-furnace gas and secondary pressure equalizing assembly using nitrogen. The BCD will be installed at the height level of 45 m. This work is unique due to the fact that the heaviest part of the BCD is the raw-material hopper, which weighs over 30,000 kg. Total weightof the equipment is over100 t.

In contrast with biconic charging devices of existing blast furnaces at the plant, the new equipment has a longer service life. According to the operating standards, biconic charging devices are to be fully replaced once a year. Only one element of the BCD, the trough, is to be replaced once a year. Service life of the BCD itself is around 15 years.

"We are using technical solutions that enable us to narrow down tolerances of the monitored parameters and ensure tightest control over consumption of all types of raw materials – noted Alexander Podkorytov, the Director General of EMZ OJSC. – In the view of the toughening competition on the steel market the reduction of pig iron production costs is of the top-priority".