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Home Energy Conservation Projects in Steel Sector Implementation of compressor units powered by electric motor to produce and supply compressed air into blast furnaces of Alchevsk Iron and Steel Works
Implementation of compressor units powered by electric motor to produce and supply compressed air into blast furnaces of Alchevsk Iron and Steel Works Print E-mail
Employer:
PJSC “Alchevsk Iron and Steel Works”
Services provided:
Energy saving project initiation, development of functional specification, criteria development of equipment selection, participation in tender as the expert organization, expert analysis of provided suggestions, accompaniment of perproject works
Project title:
Implementation of compressor units powered by electric motor to produce and supply compressed air into blast furnaces of Alchevsk Iron and Steel Works
Facility amount:
4 units
CAPEX:
$ 40 million
Supplier:
MAN TURBO AG
Project location:
Ukraine, Lugansk oblast, Alchevsk city

Project summary

The project envisages the reduction of energy consumption at PJSC “AISW” due to the usage of modern energy saving equipment on the basis of compressor aggregators for blast furnaces with the actuator from electric motor. Implementation of compressor aggregates implementation leads to the reduction of energy resources consumption almost in 2 times in comparison with the existing consumption: from 45,3 kg. o. e. /1000 m3 till 23,5 kg o. e. /1000 m3.

 

BF – blast furnace; NK – noise-killer;Ко - compressor; М – electric motor; SSMF – smooth setting in motion facility; DTFR – device of turn frequency regulation; Ф – filter.

Technical aspects of the project

The project includes the building of four compressor aggregates:
  • one aggregate with capacity of 6500 m3/min. for blast furnace № 1;
  • other two aggregates with capacity of 4200 m3/min each for blast furnace  № 3, 4, 5.

The project of blast station building at PJSC “AISW” includes also building of compressor aggregates, noise-killer systems, equipment for air suction (valves, filters) and devices for smooth setting in motion.

Total annual (perspective) production of compressed air for blast furnaces at PJSC “AISW” is equal to 10 000 000 mio. m3/year.

The existing blast tube facility with the drive of steam turbines, installed at combined heat and power plant at PJSC “AISW” is planned to be installed as the reserve blast equipment. The energy provision of electricity drives of compressor aggregates is planned to be realized with the help of the private steam and power station, which is constructed at PJSC “AISW”. The total fixed capacity of electric motors of four compressors will be 26, 39 MW.

The main techno-economic indexes of compressor aggregates


Number of blast furnace (BF) Productivity, m3/min Type of compressor Politropic efficiency, % Specific electricity consumption, kW/1000 nm3 Parameters of compressed air
BF 1 6500 axial 90,8 83,15 0,6 MPa, 244 °С
BF 3, 4, 5 4200 axial 90,5 83,45 0,6 MPa, 245 °С

Project efficiency

The project aims to improve efficiency of compressed air production for blast furnaces at PJSC “AISW” and thus the reduction of energy resources consumption is achieved in 21,8 kg o. e. /1000 m3, or in 218 ths.t. o. e. /year (producing 10 000 mio. m3 /year of compressed air).

Project socio-economic consequences

The project implementation will have the raw of socio-economic consequences for the mill and region, such as:

  • reduction of the production cost of the final production, increase of its competitiveness, and also the realization of similar products stimulation at the other steel enterprises;
  • economic condition improvement in the region due to the increase of money deduction to the budgets of all levels, including the social needs, preventing of the work places amount reduction and assistance to working conditions improvement;
  • renewal of the economic activity due to the attraction of native engineers, contractors for project implementation;
  • improvement of the general resource efficiency and also the improvement of PJSC “AISW” position at the production market.  

Similar projects have been initiated at PJSC “Dneprovsky Integrated Iron and Steel Works named after Dzershinsky”, PJSC “Yenakievo Iron and Steel Works”, PJSC “Azovstal Iron and Steel Works”, “ISD DUNAFERR” Co. Ltd. (Hungary).

 

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