Siemens VAI Metals Technologies received a contract from Kaluzhsky Scientific Industrial Electrometallurgical Plant, a company of Maxi-Group, for the supply and installation of a new steelmaking meltshop in Vorsino, Kaluzhskaya Oblast. The Siemens VAI scope of supply comprises an Ultimate-type electric arc furnace (EAF), secondary metallurgical facilities, the dedusting systems, a billet caster in addition to the media supply, electrics and automation.
The total order volume for Siemens is a two-digit-million-euro figure. The new steelmaking facility is scheduled for start-up in 2011. The meltshop of the Maxi Group, which will be capable of producing 1.5 million tons of liquid steel per year, will be built in Vorsino, Borovskiy Rayon, Kaluzhskaya Oblast, approximately 120 kilometers southwest of Moscow. The carbon and alloyed steel grades will be cast as billets and subsequently rolled at the same plant site.
For this project Siemens VAI will engineer and supply a 120-ton/150-MVA Ultimate-type AC EAF. One hundred percent scrap will be charged as the input material. By means of a scrap bucket with a volume of 195 m3 single-bucket charging will be carried out. In combination with a high electrical and chemical energy input 40 heats will be able to be tapped per day. Five RCBs (refining combined burners) and three oxy-gas burners will be installed to accelerate melting and promote postcombustion.
A 120-ton twin-station electric arc furnace and an alloying/additive system will enable the temperature and composition of the steel to be adjusted according to the casting and downstream product requirements. The dedusting system will be designed with an exhausting capacity of more than 2,000,000 m3/h of which 235,000 Nm3/h of offgas will be exhausted from the EAF during melting operations and 90,000 Nm3/h from the ladle furnace. The remaining capacity will be for the secondary dedusting of the meltshop area, including the canopy hood and alloying/additive system. A pulse-jet-type filter-bag house, including radial ID (induced draft) fans, will be installed.
The clean-gas dust content will be reduced to the contractually specified values in accordance with the local environmental regulations. The 8-strand billet caster with a curved mold and casting radius of 8.0 meters will be capable of casting approximately 1.5 million tons of billets per year in square formats of 125–150 millimeters. Various technological packages will be installed, including LevCon to control of the steel level in the mold, DynaFlex for the online hydraulic adjustment of the mold-oscillation parameters and Diamold mold tubes in support of high-speed casting. Siemens VAI will also supply the hydraulic and electrical systems, the water and gas media supply as well as basic and process automation.
Maxi-Group, to which the Kaluzhsky Scientific Industrial Electrometallurgical Plant belongs, is comprised of several enterprises for the production of ferrous metals. The company's activities extend from the collection and processing of scrap up to the manufacturing of rolled products which are used primarily in the construction industry and for other metal-ware applications. The company has focused on developing a network of minimills in regions where there is a high demand for steel and extensive scrap resources. In December 2007, Novolipetsk Steel acquired a majority stake of Maxi-Group. Novolipetsk Steel is one of the largest Russian steel producers and had a crude steel output exceeding nine million tons in 2007.