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Umanskii A.A.,Siberian State Industrial University | Mart'yanov Y.A.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK
Metallurgist | Year: 2014

Tests were performed on the continuous 250-2 light-section mill at the EVRAZ ZSMK combine to study the effect of the deformation regimes on the healability of surface defects on semifinished products. It was confirmed experimentally that increasing the degree of similarity between the pass and the cross-sectional shape of the initial semifinished product increases the healability of the defects. A new pass system was developed for the rolls in the roughing-stand group of the 250-2 mill. Introduction of the new system has increased usable output 3% by reducing the incidence of rejections due to surface defects. © 2014, Springer Science+Business Media New York.


Bogatishchev V.V.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK
Metallurgist | Year: 2014

This article describes work done at the EZRAZ ZSMK on improving the efficiency of the combine's lighting systems and finding optimum ways to upgrade them. The objectives and initial results of a program for making the systems more efficient are also discussed. © 2014, Springer Science+Business Media New York.


Volkov K.V.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK | Kolotov E.A.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK | Syusyukin A.Y.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK
Metallurgist | Year: 2014

Engineers and scientists in Russia and abroad are giving a considerable amount of attention to improving the quality of the rails being made by metallurgical plants. Rolling 100-m-long rails requires proper preheating of the continuous-cast semifinished products with a minimal temperature gradient along and across the products. A heating operation of the requisite quality is assured by the use of a level-2 automation system to heat the metal in the furnace. © 2014, Springer Science+Business Media New York.


Feoktistov A.V.,Siberian State Industrial University | Odintsov A.A.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK
Metallurgist | Year: 2014

Results are presented from laboratory studies of the sintering of a two-layer charge in which the solid fuel is separated into different fractions. It was established that a reduction in the top layer’s content of the –0.5-mm fraction from 45% to zero is accompanied by a decrease in the unit productivity of the sintering machine and increases in the output of sinter and its strength characteristics. The indices of the sintering operation and sinter quality remain the same as in the standard technology when fuel content is decreased from 7.5 to 7.1–7.2%. Introduction of the technology that was developed will makes it possible to decrease the unit consumption of solid fuel for sinter production by 4%. © 2014, Springer Science+Business Media New York.


Portnov L.V.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK | Nikitin L.D.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK | Bugaev S.F.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK | Shchipitsyn V.G.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK
Metallurgist | Year: 2014

When blast furnaces are forced to run at high speed, one way of reducing their downtime, increasing their productivity, and lowering the cost of making pig iron is to improve the durability of the tuyeres. Experience shows that the main causes of tuyere failure are crack formation, wear, and burn-throughs. The durability of a tuyere and the type of problems encountered with it are significantly affected by the sophistication of the smelting technology that is used and the quality of the charge materials. Most tuyeres do not last longer than three months when the supply of raw materials to the furnace is unstable, and 20% of tuyeres (out of the total number that are replaced) have lasted less than half a month under such conditions. The amount of furnace downtime necessitated by the replacement of failed tuyere parts has reached 2.0–2.5% of nominal operating time, which has seriously hurt furnaces’ technical-economic indices. Stabilization of the operation of blast furnaces at EZRAZ ZSMK has allowed the combine to work on improving the durability of the tuyeres by redesigning them, improving the quality of the work done in making them, and applying protective coatings (by plasma deposition, electron-beam hard facing, etc.). The combine’s introduction of a new technology for making tuyeres and the strengthening of these pieces of equipment while ensuring a satisfactory cooling rate have made it possible to reduce the incidence of tuyere failure due to cracking. The number of tuyere replacements has declined during both normal and high-speed operation of the furnaces, which has in turn elevated tuyere service life to an average of 5–7 months and a maximum of 14–15 months. © 2014, Springer Science+Business Media New York.


Shentsov A.I.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK | Odintsov A.A.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK | Svirin E.B.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK
Metallurgist | Year: 2014

are presented from the implementation of several technical and technological measures aimed at making sinter production at EZRAZ ZSMK more efficient. The measures have elevated the technical-economic indices of the sinter plant, increased sinter output, reduced sintering-machine downtime, and improved the sinter's quality characteristics. © 2014, Springer Science+Business Media New York.


Mezentsev M.Y.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK | Shabis A.G.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK
Metallurgist | Year: 2014

Stages in the realization of the Repairs project at the EVRAZ ZSMK combine are examined. Data are presented on the tools of lean manufacturing and the methods used to implement it. The problems typically encountered at the different stages of the project are discussed. © 2014, Springer Science+Business Media New York.


Golubtsov S.N.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK | Karakash K.P.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK
Metallurgist | Year: 2014

One environmental problem that has become particularly important is reducing pollution from coke production. One of the steps that has been taken to help solve the problem is the introduction of a dust-free coke discharge unit at EVRAZ ZSMK. © 2014, Springer Science+Business Media New York.


Yuryev A.B.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK
Metallurgist | Year: 2014

EVRAZ Consolidated West-Siberian Metallurgical Combine is one of the largest metallurgical enterprises in Russia. It is part of the vertically integrated international mining-metallurgical company EVRAZ, which operates facilities in Russia, Ukraine, Kazakhstan, the U.S., Canada, Italy, and South Africa. © 2014, Springer Science+Business Media New York.


Brinza V.V.,Moscow Institute of Steel And Alloys | Kuznetsov I.S.,EVRAZ Consolidated West Siberian Metallurgical Combine EVRAZ ZSMK
Metallurgist | Year: 2014

It is proposed that results obtained from the experimental-theoretical solution of a three-dimensional problem on the plastic flow of metal be used to determine the main reasons for variations in the output of usable metal products. The results were obtained on the basis of models of quality. Modeling was performed to analyze a technology for rolling a broad range of structural-grade carbon-steel rounds that then undergo cold extrusion and upsetting. The rounds are rolled on a light-section mill and a rod mill at the EVRAZ ZSMK combine. It is shown that under the given production conditions the value of the integral index of rolled-product quality which characterizes the output of usable metal over long periods of time is determined mainly by simultaneous processes that involve the healing (or deepening) of surface defects, the formation of cracks on the surface of the semifinished products, nonuniform wear of the grooves of the rolling-mill passes, and depletion of the reserve ductility of the metal in the region where it comes into contact with the grooves. The results have been used to substantiate corrective measures taken in the multi-stage manufacture of rolled products at the combine. The measures were substantiated within the context of the combine's existing quality-control system. © 2014, Springer Science+Business Media New York.

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