Magang completes new factory project

Friday, 21 September 2007 17:02:05 (GMT+3)   |  
       

SteelOrbis Shanghai

On September 20th Magang's new factory project was put into production after the successful completion of construction. The new project has a raw steel production capacity of 5.85 million metric tons, having been built with a total investment of RMB 20 billion ($2.66 billion). Located in Cihu Lake, northwest of Ma'anshan City, the project is connected to Magang's existing factory space and covers an area of 36,000 square meters.

The steelmaking system of the new project consists of two 4,000 cubic meter modern blast furnaces with a total designed capacity of 6.5 million metric tons. It includes auxiliary equipment such as two 360 square meter sintering machines with a combined designed capacity of 8.3 million metric tons, and also a 7.63 meter coke furnace with a capacity of 2.2 million metric tons.

For over two years from ground breaking to full operation, Magang's new area project has seen the the five million metric ton integrated production line go through the various stages from sintering, ironmaking, steelmaking to hot rolling, cold rolling and galvanizing. Thus, Magang's expanded production scale of 16 million metric tons of raw steel has finally come into being.

The steelmaking and continuous casting system is an optimized combination of four processes, from pretreatment of hot metal, converter smelting, external refining to continuous casting. By taking the features, scale and quality of sheet products into account and matching them with the varieties and specifications of the current CSP and medium plate production lines, the steelmaking and continuous casting system can achieve maximum efficiency. With a designed capacity of 5.85 million metric tons for raw steel, the new steelmaking system is able to produce a series of high quality and high value added products such as low-alloy structural steel, deep punching steel, extra-deep drawing steel, automobile steel, boiler steel, pressure vessel steel, shipbuilding steel, corrosion resistant steel, pipeline steel and duplex steel.

The hot rolling system has employed an optimized common hot-rolling process, from walking beam furnace, side pressing, roughing, finish rolling to recoiling, which can conduct offline detecting and clearance on the feedstock produced by continuous casters. In doing so, the stability and reliability of the feedback quality can be ensured from the very beginning, so as to guarantee the surface quality of sheets. Meanwhile, since the raw slabs used for common hot rolling are relatively thick, a relatively high rolling reduction ratio can be realized. As a result, the sheets made from such slabs can feature low yield ratios and high forming properties, which cannot be realized by shorter process. Its designed capacity is 5.5 million metric tons.

The cold rolling and galvanizing system utilizes the following processes: pickling and continuous cold rolling, continuous hot dip galvanizing, continuous annealing, and recoiling. The pickling process and continuous cold rolling can be used to produce soft steel series and high strength cold rolled sheets while the hot galvanizing lines focus on the production of inner & outer panels for top grade cars, panels for high class home appliances as well as some construction plates. With a designed capacity of 2.1 million metric tons, the system is able to produce high quality products with relatively high efficiency.

Meanwhile, in order to greatly improve recycling economy, the new area will also see the construction of a gas-steam combined cycle power generation set (CCPP) with 153 megawatts and a blending blast furnace gas power generation set synchronously, as well as dry extinguished coke, TRT and agglomerate waste heat power generation equipment to take full advantage of the exhaust gases, residual pressure and waste heat. The power generated is 2.5 billion kilowatt-hour annually, and the proportion of power generated by itself is as high as 60 percent, thus comprehensive use of energy can be achieved. The first comprehensive sludge utilization project will also be developed to recycle all sludge from blast furnaces and convertors. An advanced online treatment system for steel scoria will be established to sort out and dispose of all solid waste produced during the production process for efficient utilization by using new granulation technology. Two waste water collection treatment systems will be built to treat waste water. Most of the post-treatment water will be used in workshops while the rest will be discharged in line with corresponding standards. Nine living waste water collection & treatment systems will be developed to purify waste water up to the quality standard of intermediate water. Thus, the waste water resources can be recycled so as to reduce the consumption of fresh water. The major energy environmental protection design indexes are as follows: comprehensive energy consumption per ton of steel is 669 kg of standard coal equivalent; comparable energy consumption per ton of steel is 649 kg of standard coal equivalent,; fresh water consumption per ton of steel is 3.84 stere, with 97.5 percent of circulating rate; dust emission per ton of steel is 0.3 kg; SO2 emission per ton of steel is 0.25 kg.


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