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Home Energy Conservation Projects in Steel Sector Introduction of combined cycle power plant with capacity of 454,5 MWe based on waste steel gases at Alchevsk Iron and Steel Works
Introduction of combined cycle power plant with capacity of 454,5 MWe based on waste steel gases at Alchevsk Iron and Steel Works Print E-mail
Employer:
PJSC “Alchevsk Iron and Steel Works”
Services provided:
Initiation of energy saving project, development of functional specifications, participations in tender as expert organization, expert analysis of propositions, accompaniment of preproject, project and building works
Project title:
Introduction of combined cycle power plant with capacity of 454,5 MWe based on waste steel gases at Alchevsk Iron and Steel Works
Amount of equipment units:
3 units
CAPEX:
$ 690million
Supplier:
Mitsubishi Heavy Industries Ltd.
Project location:
Ukraine, Lugansk region, Alchevsk city

Project summary

The project envisages the reduction of energy consumption at PJSC “AISW” due to the usage of the modern energy saving equipment on the basis of steam and power stations (SPS), which as a fuel use only fuel secondary energy resources (SER) – steel gases (blast furnace, coke oven and converter gases). SPS implementation leads to the reduction of natural gas and electricity consumption,  and also to own electricity prevision almost in 100%. SPS exploitation PJSC “AISW” includes the usage of natural gas for energy production, and also leads to the reduction of energy resources consumption in 2…2,5 times in comparison with existing consumption: from 546…683 g o. e. kW-g till 273 g o. e. /kW-g.


Technical aspects of the project

The project includes building of:
  • the first steam and power electricity station (SPES) with total capacity of 303 MW, which consists of two SPS with the electric  capacity of 151,5 MW each of them;
  • the second turn of SPS with the capacity of 151,5 MW, which consists of one SPS.

Total electric capacity of SPES at PJSC “AISW” is 454,5 MW.

The SPES project includes SPS building, which consists of steam and gas turbines, compressors of fuel gases and air, generators, and also heat boilers. Besides the project has to be provided with gas pipelines of steel gases, gasholders and also some other subsidiary equipment

Total annual (perspective) electricity production at SPES is equal to 3, 6 bln. kW-h.

Produced electricity at SPES will be entirely used for own needs of steel mill.

The main techno-economic indexes of compressor aggregates


Fixed capacity of CCGT, MW Electricity production, mio. kW-h/year Effectiveness of electricity production, % Fuel wastes, г у. п./кВт-г Fuel gases (mixture)
151,5 1200 45 273 Blast furnace
Coke oven
Converter

Project efficiency

The project mainly aims to raise the effectiveness of SER usage (steel gases), and also to reduce steel mill wastes for purchasing energy resources – natural gas and electricity in the way of own electricity production. STS implementation at PJSC “AISW” leads to the reduction of natural gas consumption in 835 mio. m3/year.

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 OJSC “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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