Kametstal's Furnace Overhaul
Kametstal, a major player in the steel industry, has recently completed a major overhaul of its fire heating furnace used for waste oil recovery in its coking chemicals recovery shop. This strategic upgrade is set to optimize the technological process and reduce energy expenses. The modernized unit is essential for heating absorbent oil before it enters the benzene column in the production of crude benzene. The heat generated by the furnace is crucial for maintaining the stability and efficiency of this process, which is integral to the plant’s overall operations.
The Role of the Fire Heating Furnace
The primary function of the fire heating furnace is to heat the absorbent oil to a temperature range of 135-160°C. This step is necessary before the oil is fed into the benzene column for further processing. In addition to performing this vital function, the furnace helps Kametstal reduce the cost of steam production, as it uses coke oven gas, a byproduct of the steel production process, as a heat source. Utilizing coke oven gas is more cost-effective than purchasing external steam, offering substantial savings in operational costs.
Upgrades During the Overhaul
The modernization process involved several key upgrades designed to boost efficiency and enhance safety:
1. Heat-Resistant Steel Tubular Coils:
Kametstal replaced the old tubular coils and bends with new components made of heat-resistant steel. This change ensures that the furnace can utilize its heating surfaces more effectively, thereby increasing its overall efficiency. The enhanced material will withstand the high-temperature conditions within the furnace, reducing the need for frequent maintenance.
2. Upgraded Heating System:
The heating system itself was also overhauled. Kametstal replaced its coke oven gas burners and installed new shut-off valves to improve operational control. Additionally, the gas outlet control system was restored to optimize the flow of gases, further contributing to efficient energy use.
3. Improved Safety Features:
Kametstal placed a strong emphasis on labor safety during the overhaul. The furnace service areas were restored, ensuring that these zones remained reliable and safe for maintenance personnel. The furnace’s bottom was sealed to prevent combustion product leaks, safeguarding both the workers and the environment.
Benefits of the Modernized Furnace
The primary benefit of this modernized furnace is the significant reduction in energy costs. By using coke oven gas instead of purchasing expensive steam, Kametstal can reduce its overall production costs. Moreover, the increased efficiency of the furnace ensures that the technological process of producing crude benzene remains stable and reliable.
The furnace is not only more cost-effective but also aligns with Kametstal's commitment to improving its environmental footprint. By optimizing energy consumption, the company can lower its carbon emissions and contribute to its long-term sustainability goals.
Recent Developments at Kametstal
This furnace overhaul is part of a broader investment strategy by Kametstal to modernize its facilities. The company has also completed a major overhaul of its medium-pressure boiler unit No. 6, which has a capacity of 90 metric tons of steam per hour. The refurbishment of this unit ensures a stable steam supply to the plant, which is crucial for continuous production.
Kametstal is also planning a significant increase in investment for 2025. The company intends to invest UAH 2.5 billion in the modernization of its production facilities, marking the largest investment in recent years. Among the key projects is the overhaul of blast furnace No. 9, as well as the construction of a solar power plant. These projects reflect Kametstal's commitment to improving both production efficiency and environmental sustainability.
Future Outlook and Strategic Goals
The modernized heating furnace for waste oil is just one of many improvements that Kametstal has implemented to ensure the sustainability and competitiveness of its operations. With continued investments in energy-efficient technologies and eco-friendly solutions, Kametstal aims to maintain its position as a leader in the global steel market while contributing to the economic development of the region.
Kametstal’s focus on cost reduction, technological advancements, and sustainability positions it for long-term success. The company is not only enhancing its operational capabilities but is also ensuring that it can meet future challenges, such as rising energy prices and increasing environmental regulations.
Key Takeaways:
• Kametstal’s modernized fire heating furnace in the coking chemicals recovery shop aims to stabilize the production process and reduce energy costs.
• The furnace uses coke oven gas as a heat source, which helps lower the need for expensive external steam.
• Key upgrades include the replacement of tubular coils and bends with heat-resistant steel and the installation of new coke oven gas burners and shut-off valves.
• Kametstal also prioritized safety during the overhaul, ensuring the reliability of the furnace and preventing combustion product leaks.
• The furnace modernization is part of Kametstal’s broader effort to reduce energy costs and improve operational efficiency.
• In 2025, Kametstal plans to invest UAH 2.5 billion in further modernizing its facilities, including the overhaul of blast furnace No. 9 and the construction of a solar power plant.
Kametstal’s investments in modernization are setting a solid foundation for energy-efficient production and sustainable growth, ensuring the company’s competitiveness in the evolving global steel market.
