Modernization of manufacturing facilities

Technologies and innovations

 

2016

 


Materials for the furnace lining.


At ISD Dunaferr, Hungary, on 08.07.2016 blast furnace No. 2  was successfully commissioned <http://www.dunaferrmagazin.hu/index.php/rovatok/aktualis/1307-befejezodoett-a-kohofelujitas>.  A full  set of  carbon and graphite part of the blast furnace lining, that is more than 750 tons of products was  manufactured by  PJSC "Ukrgrafit" in  2015-2016.


3 grades of graphite and carbon blocks, including micropore blocks, and also 2 grades of carbon-based pastes were used.


Technical divisions of PJSC "Ukrgrafit" were involved in the development of the design of the furnace lining, namely the central research laboratory, the technological department, the design department, etc.


Due to efforts of production divisions of PJSC "Ukrgrafit", test preassembly of 14 courses of block lining  for  BF No.2.  was carried out  in a timely manner


ISD Dunaferr possesses two operating blast furnaces. For today  both furnaces contain lining materials produced by PJSC "Ukrgrafit".  The  management of the integrated works prefers   those material on the basis of their  experience in operation of products to  European and Chinese manufacturers of similar products.


 


Graphite electrodes


In 2015-2016,  manufacturing of graphite monoelectrodes Ø 200-250 mm started.


After successful tests of trial lots of monoelectrodes we received an order for their  commercial  delivery.


The  monoelectrodes performed well that  allowed us to gain a new sales market.


For measuring geometrical dimensions of electrodes modern measurement instrumentation has been purchased. Machining is carried out by  modern  VIPER NC  lathe.


 


Large-block pastes.


PJSC "Ukrgrafit" launches manufacturing of a new type of large - block rectangular  Soderberg electrode paste (LBEP). At present  LBEP 400-900 mm  in diameter, 850-1100 mm long is produced. The distinguishing feature of the rectangular LBEP is that the above product does not require packaging and this  makes it possible not to use  expensive wood. Also the LBEP storage area at the consumer will be considerably reduced.


Launching of the rectangular LBEPs will make it possible to enter new sales markets in America, Africa, etc.


 


Cathode blocks for the most powerful electrolysis cells in the world.


In February 2016, PJSC "Ukrgrafit" delivered 3 sets of PB10 graphite bottom blocks 3980 mm for RUSAL, intended for  a new  РА-550 electrolysis cell, fundamentally new design  for  future RUSAL's plants and modernization of its existing plants. According to calculations, the capacity of the new equipment will increase in comparison with the previous versions of electrolysis cells - РА-300 and РА-400  by  50-80 % and will exceed four tons of metal per day.


Previously, it is with the use of bottom blocks manufactured by Ukrgrafit  the production of РА-300 electrolysis cells was launched which were installed at the Khakassky and Boguchansky aluminium plants. In 2006-2007 for start-up of  the Khakassky aluminium  plant Ukrgrafit delivered 8 thousand tons of bottom blocks.


 


             Cathode blocks with improved resistance.


According to arrangement with one of the world leaders in the production of aluminium in the Middle East, for 2016 delivery of two grades of graphitized bottom blocks with the increased resistance to abrasive  wear  for operational tests was planned.


It is common knowledge that graphite bottom blocks have one disadvantage, that is 1,5 to 2 years shorter  life time, than that of anthracite and graphite blocks, accordingly, due to higher wear. Better resistance to abrasive wear of graphite blocks solves the problem of low life time of electrolysis cells.


 

2015


Cold-ramming paste.


RUSAL, Krasnoyarsk performed laboratory tests of MHNP cold-ramming bottom paste manufactured by PJSC "Ukrgrafit". The results have satisfied RUSAL requirements, operational tests, two railcars with MHNP paste at Krasnoyarsk and Sayanogorsk aluminium plants are being carried on.


 


Within 2013-2015, in comparison with the preceding periods, PJSC "Ukrgrafit" has built up production volumes and sales of cold-ramming pastes for use in blast and other metallurgical furnaces.


Consistently high quality of the  product made it possible to obtain such results and, as a consequence, long-term contracts with consumers from Ukraine, Kazakhstan and the EU countries were concluded.


 


Materials for the furnace lining.


In 2015,  the central research laboratory  at PJSC "Ukrgrafit" manufactured samples of carbon blocks for the lining of metallurgical furnaces with additives which improve resistance of the material to penetration of liquid melted products. The above work was  performed with the purpose of increasing the service time of the lining in the most stressed areas, for example,  tap hole areas of blast  and ferroalloy furnaces. At present search for proper  methods of assessments of resistance of the carbon block samples in industrial conditions.


 


Anodes for the magnesium industry.


In 2015,  within a special program of development we continued testing of new anodes out of bars with increased dimensions: up to 2921 mm long, up to 703 mm wide and with thickness of up to 250 mm, and also glued "standard" top  (AV) and bottom (AN) mounted anodes with various widths out of  separate anode bars.


 


Glued anodes:


Trial industrial tests of AN anodes glued out of  two bars of AN and AV anodes  (with protective impregnation against oxidation) are carried out.


 


Monoanodes - are  anodes consisting of one large-sized bar:


Trial industrial consignments of AN and AV anodes (with protective impregnation against  oxidation) out of  bars of BN grade are being tested by foreign consumers.


 


Large-sized graphite bars.


We are developing manufacturing of anode large-sized bars of BN, BV and BMV grades for manufacturing of  AV and AN anodes. Within  joint programs with consumers we are testing in industrial conditions  the anodes manufactured out of those bars, including:


- AV and AN up to 1650 mm wide  out of  BN, BV and BMV bars up to 660 mm wide.


 


Preparation for production of advanced products: 


The process was developed and semifinished products for the consequent manufacturing of trial ВN anode bars with dimensions 183х686х2921 mm, 183х457х2921 mm, 250х600х2420 mm, 60х703х1250 mm and 60х691х1250 mm designed for advanced electrolysis cells on the existing and new markets.


 

2014


Graphite electrodes for ultra high power steel furnaces.


In 2014,  we started manufacturing of EGSP Ø650 mm graphite electrodes for which a  new die was manufactured. Also a recipe was found,  using which  good  well-formed electrodes were  produced at the first attempt.


The above electrodes are intended for large UHP steel furnaces (over 150 mt of  metal in one heat).


In 2014,  Dneprostal, Dnepropetrovsk  successfully tested EGSP (UHP) electrodes  Ø 650 mm 2700 mm long. Those electrodes performed similarly to  European analogues (UCAR, SGL Carbon).


 


Bottom blocks with the increased resistance to abrasive wear.


In 2014, the technology for graphitized bottom blocks with the increased resistance to the abrasive wear was developed and a trial lot of blocks was manufactured. Assessment of the abrasive wear of blocks was performed in an independent laboratory (R&D, Switzerland). The resistance to the abrasive wear of the trial lot of the graphitized bottom blocks is 44,5 %  higher than that of the blocks manufactured with the use of the common technology.


 


Cathode products.


In order to satisfy the requirements of consumers and to expand the sales market of cathode products,  in 2014, independent laboratory of ELTER Scientific and technical center  carried out high-temperature test (20-1000ºС)  of PB3, PB10, PBG, PBG-2 bottom blocks. Test results confirm conformity of the characteristics of the products with the consumers' expectations.


Anodes for the magnesium industry.


In 2014, within the programs of development fine-tuning of the technology, manufacturing and testing of standard and trial anodes out of  bars with increased dimensions up to 2921 mm long, up to 703 mm wide and up to 250 mm thick, and also glueing of "standard" anodes having various widths out of  separate anode bars.


 

 

Efficient operation of the enterprise is impossible without introduction of the latest technologies and modern process equipment, without development of new carbon of materials and expansion of the range of products, without constant increase of technological level and quality of fabricated products.

Over the last few years a lot of work has been done to improve products and manufacturing processes, a lot of programs and projects have been implemented. 

High-efficiency screening units of new generation ensuring high purity of useful fractions of raw materials during their processing; automated control systems for classification, mixing and extrusion in a mixing and pressing workshop; an apparatus for monitoring bulk density of blanks by hydrostatic weighing have been introduced. 

The systems of vacuum degassing of moulding mix during the moulding of raw materials on the graphite production line, and also a special modern baking furnace with automated system of running the process have been introduced. The line for machining large-sized electrodes (400 mm and over ) with capability of machining of blanks up to 3000 mm long has been modernized. For updating the graphitization technology the 3-d mathematical model of temperature fields of the graphitization furnace has been developed and introduced which will allow achieving optimization of the manufacturing process and improving technical and economic indicators of the graphitization workshop.

High-efficiency high-speed EIRICH mixer (including dosing units for auxiliary materials, preheater for the working mixture, high-speed mixer with cooling system and conveyors for supply of paste to presses) on the carbon and graphite product production line, efficient and precision automated Wassmer line for machining of cathode blocks have been put into operation.

A test ground for dry test preassembly of the elements of the lining has been modernized, which allows test preassembly of carbon linings for any existing designs of industrial furnaces. 

Modernization and specialization of baking furnaces No.7 and No.10 in workshop No.3 which made it possible to lower the consumption of natural gas by 30 % and improve baking due to minimum temperature differences at the height of the material to be baked has been carried out 

Technologies have been developed and production of new types and grades of products for the lining of metallurgical furnaces, anodes and cathodes for aluminium and magnesium industry, electrodes and electrode pastes for steel and ferroalloy industry, and also other electrical thermal productions has started

At present PJSC «Ukrgrafit» has large technological and intellectual potential, there is a team of professional managers and experts, the enterprise is equipped with modern research equipment such as: NETZSCH dilatometer, EIRICH mixer, apparatus for determination of bulk density and thermal conductivity of loose materials, Brookfield viscosimeter etc.. The metrological base of the enterprise has been re-equipped and today we have up-to-date measurement tools, control and measurement instruments, systems of marketing research, development of new types of products and launching of technology of their production at the enterprise have been created. 

Today everything is ready for implementation of the projects and planned programs. In the near future according to the plans of the enterprise the following will be done:
• construction of new up-to-date lines for machining electrodes achieving high purity and accuracy of machining of the products;
• improvement of the existing graphitization technology and also expansion of production and introduction of up-to-date lengthwise graphitization facilities;
• improvement of anode paste production with application of up-to-date equipment and automated systems;
• implementation of technology and starting production of new grades and types of products to satisfy the present and future demands of traditional consumers of carbon and graphite products.

At present PJSC «Ukrgrafit» has far-going ideas in the field of improvement of commercially produced products, and in the field of creation of new kinds of products focused on the future requirements of consumers, expansion of the range of application of materials and products based on carbon. 

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