What is metallurgy, what role does it play in the life of mankind? This industry is the foundation and foundation of the entire industry. Most of all areas of production use the results of metallurgical production. What is the importance of metallurgy?

The concept of metallurgy

Metallurgy plays an important role in all industries.

This term is commonly understood as a branch in science and technology that is engaged in the production, extraction of metals and ores. It is impossible to imagine technical progress without metallurgy. This is a powerful industry that improves every year the methods of extraction, studies the composition and properties of metals, and develops the boundaries of their application.

What does metallurgy include:

metal production;
processing of metal products in hot and cold form;
welding;
deposition of metal coatings.

In addition, metallurgy includes some aspects:

science, theoretical study;
knowledge of chemical processes;
study of metal properties.

The metallurgical complex unites all enterprises that are engaged in the extraction and processing of metals. These are enterprises that are engaged in ore beneficiation, rolling production, processing of secondary raw materials.

What is metallurgy? The industry is divided into two main types. Types of metallurgy:

colored.

The level of the economy and the well-being of the population depend on how the metallurgical complex develops in the country.

Metals and alloys have a number of useful properties. These include:

elasticity;
ability to deform;
high strength;
thermal conductivity.

Due to their properties, metals and alloys are among the most important materials that are used in the creation of modern machines and technology. The central place is occupied by iron, its share in metallurgical products is more than 90%.

But the iron pure form used in small quantities. The bulk is used in the form of alloys.

The most commonly used steel and cast iron, which are ferrous metals. Steel is the main type of metal in ferrous metallurgy, it has high strength and wear resistance. And steel lends itself well to welding.

Ferrous metallurgy is a branch of heavy industry, which includes in its technology the very extraction of material, processing, filling production with auxiliary materials and fuel.

In addition, ferrous metallurgy includes the final release of products and their processing. This type of industry includes:

obtaining the main raw materials;
enrichment of primary material (manganese and iron ore);
smelting of cast iron, as well as high-quality steel;
execution of refractory materials;
filling production with auxiliary materials (limestone);
production of metal products for own use.

Ferrous metallurgy is the basis of the entire engineering industry. Ferrous metals are widely used in construction and for human needs.

In terms of the concentration of black metal, Russia occupies a leading position in the world compared to other industrialized countries.

In the structure of ferrous metallurgy, an important place is occupied by the stage of production of iron and steel up to the moment of rolling. In addition, production is based on the preparation of the ore itself for remelting, as well as enrichment.

For the production of pig iron, in addition to ore, the preparation of fuel and refractory materials is required, which help to achieve high-strength qualities from the metal. Coke is most often referred to as technological fuel; high quality coking coal is used for its production.

The subtleties of production

The location of enterprises associated with the extraction and processing of ferrous metals directly depends on the factor of raw materials. It is he who accounts for 90% of the costly funds in the remelting of cast iron.

Part metallurgical complex Russia has three main bases:

central;
Siberian;
Ural.

In recent years, the Central Base has been increasing production rates and surpassing the Ural one. It fully supplies the entire Central part of Russia with coking coal and ores. The bulk of the metal is produced in Cherepovets and Lipetsk.

The center of the Siberian base is the city of Novokuznetsk. This base has perspective value as it is completely based on the resources.

The Ural base is located in close proximity to fuel-rich Siberia and Kazakhstan. This location provides a low cost of production. In addition, a great advantage is the location close to Ural mountains. They are very old and nowadays many of them are being destroyed. Therefore, mining is carried out practically on the surface.

Most metals and ores can be mined.

But there is a downside to this location. There is no coking coal here, it has to be imported from neighboring regions.

Metallurgical plants with small capacity are of great importance in the country. It is they who can ensure the rapid smelting of metal in a small amount. Small factories respond to market changes faster than large enterprises, they are able to quickly adapt to consumer needs.

A new direction in the industry today is blast-furnace or coke-free metallurgy. Such an enterprise was built in Russia, or rather, in the city of Stary Oskol - the Oskol Electrometallurgical Plant.

The traditional process, in which the ore is melted at a temperature of 1.6 thousand degrees, along with coke, which serves as a chemical reducing agent, differs from this technology.

The new method significantly saves coke, resulting in an environmentally friendly metal of high quality. Processes associated with coking coal are becoming more and more unprofitable every year.

Coal becomes more expensive, the coking process is very complicated, it requires additional costs, the construction of additional treatment facilities.

New installations are practically harmless to the environment. In addition, steel produced using the new technology lasts five times longer.

Russia ranks fifth in the world in the production of this metal. In terms of explored reserves, the state is in second position.

The emphasis in the search for a location is on the development of primary deposits. The main places of gold concentration are in Siberia, the Far East and the Urals.

The main mines are:

Solovyevsky - an old but significant mine in the Amur region;
Nevyanovsky - was opened in 1813;
Gradskoy - the first diamond in Russia was found here;
the youngest Condor mine was discovered in the 60s, both gold and platinum are being mined here;
Altaic.

The leading position in production is occupied by Polyus Gold. She has opened mines in the Irkutsk region, the Amur and Magadan regions.

State Total

At present, Russia occupies a leading position in terms of iron ore and nickel reserves. More than 70 different metals and elements are produced in the country. Metallurgical production is of great economic importance.

The metallurgy industry is one of the most dynamically developing industries. Despite high competition from large developing countries, Russia manages to maintain its leadership due to low production costs.

The metallurgical complex has its own problems. The growth of production at most enterprises occurs only when new production capacities are created. Most of them were created more than 50 years ago, but they have already exhausted their reserve.

Video: Metallurgy

Metallurgy is adjacent to the development, production, operation of machines, equipment, units used in metallurgy. prom.

To study the laws of the processes of concentration, extraction, production, refining and alloying of metals, as well as processes associated with changes in the composition, structure and properties of alloys and materials, semi-finished products and products from them in metallurgy, physical, chemical, physical .-chem. and mat. research methods.

M Metallurgy is divided into black and non-ferrous. Ferrous metallurgy covers the production of iron, steel and ferroalloys (see Iron alloys). Metallurgy is closely related to coke chemistry, the production of refractory materials. Ferrous metallurgy also includes the production of rolled products, steel, cast iron and other products (ferrous metals account for ~ 95% of all metal products produced in the world). In the 70s. there was a tendency to replace ferrous metals with aluminum and titanium alloys, as well as composite, polymer, ceramic. materials, which, together with the high quality of metals produced and the low metal intensity of products in the industrially developed capitalist. countries led to a decrease in the volume of production of ferrous metals in these countries (Table 1).

Table 1.-PRODUCTION OF STEEL AND CAST IRON IN A NUMBER OF COUNTRIES, MN.T

* Data for 1985. ** Data for 1982.

For example, in the USSR in 1988 the consumption of steel and fiberglass was resp. 160 and 6 million tons, while in the USA - 100 and 28 million tons.

Non-ferrous metallurgy includes the production and processing of non-ferrous and rare metals and their alloys. Along the way, prom-st colormetallurgy produces dec. chem. comp., materials, miner. fertilizers, etc. Metallurgy, processes are also used for the production of semiconductor materials (Si, Ge, Se, Te, As, P, etc.), radioactive metals. Modern metallurgy covers the processes of obtaining many. periodic elements. systems (except gaseous). Volumes of production (1987) of certain non-ferrous metals (thousand tons): USA-Al 3200, Cu 1560, Zn 260, Pb 330 (metal in mined ore); Japan-Al 41, Cu 980, Zn 666, Pb 268; FRG-Al 737.7, Cu 421.2 (1986), Zn 370.9 (1986), Pb 366.6 (1986).

Modern metallurgical production includes the following. technol. operations: preparation and enrichment of ores; hydrometallurgical (see Hydrometallurgy), pyrometallurgical. (see Pyrometallurgy, Metalothermy), electrothermal. and electrolytic. metal extraction and refining processes; obtaining products by sintering powders (see Powder metallurgy, Sintering); chem. and physical metal refining methods; melting and pouring of metals and alloys; processing of metals by pressure (rolling, stamping, etc.); thermal, thermomechanical, chemical-thermal and other types of metal processing to give them the required sv-in, etc .; processes for applying protective and hardening coatings (on metals and metals on products).

In enrich. technologies naib. widespread flotation., gravitational., magn. and electrostatic. enrichment methods (see Mineral enrichment, Flotation). Flotation. processes are used to enrich more than 90% of non-ferrous and rare metal ores. The concentrates obtained after enrichment are subjected to drying, composition averaging, mixing and agglomeration (agglomeration, pelletizing, briquetting) in order to increase their reaction. ability and performance of their last. redistribution.

As a result, pyrometallurgical processes (include oxidation, reduction, etc.) the metal is concentrated and impurities are removed into the resulting phases (vapor-gas phase, metallic and slag melts, matte and solid matter). After separation, the phases are sent for processing for further extraction of valuable components. For the intensification of the metallurgical processes (in converters and autoclaves), gaseous O 2 , Cl 2 and other oxidizing agents are introduced. C, CO, H 2 and active metals are used as reducing agents. Common restores. processes - blast-furnace smelting, smelting of secondary Cu, Sn and Pb in shaft furnaces, production of ferroalloys and titanium slag in ore recovery. electric furnaces, magnifier-mich. restoration of TiCl 4 to obtain metallic. Ti. Oxidize refining has been developed in open-hearth and converter steel production, in the production of anodic Cu and in Pb technology. For extraction and refining of metals found application tehnol. processes using chlorides, iodides and carbonyls of metals, as well as distillation, rectification, vacuum separation and sublimation, etc. Out-of-furnace methods of steel refining, processes in vacuum and Ar environment in the technology of highly reactive metals (Ti, Zr, Nb, etc.) .

The production of products with special properties and high quality is carried out by powder metallurgy, which makes it possible to achieve higher technical and economic. performance compared to traditional. ways. To obtain high-purity metals and semiconductor materials, zone melting, the growth of single crystals by drawing from melts, and other methods are used. Main direction of tech. progress in the field of obtaining castings from the melt. metals and alloys is the transition to continuous casting of steel and alloys and to the combination of casting and metal forming processes (non-ingot rolling of Al, Cu, Zn, etc.).

Metal forming, forging and stamping production and pressing are the most important technologies. metallurgical processes. and mechanical engineering. enterprises. Rolling-basic method of processing metals and alloys. It is carried out on rolling mills - powerful highly automated. aggregates with a performance of several. million tons of rolled products per year. Rolling produces sheet and section metal, bimetals, pipes, bent and periodic. profiles and other types of products. The wire is obtained by drawing.

Thermal processing includes hardening, annealing and tempering of metals. In addition to the processing of finished parts for machine building. enterprises, heat treatment is subjected to many. types of products for metallurgical. factories - steel rails (volumetric hardening or head hardening), thick sheets and reinforcing steels, thin sheets from transformer steel, etc. Great importance in metallurgy, they have processes of chemical-thermal treatment and application to metal decomp. protective coatings, eg. galvanizing, tinning (see Electroplating), applying plastics, etc.

Modern metallurgy is characterized by emissions into the environment (tab. 2.3), in the USSR, also negligible. the use of continuous casting of steel, low return of metals for reuse, low complex use of raw materials and abs. the predominance of steels in the balance of metals (95%).

Tab. 2.-EMISSIONS (T/DAY PER 1 MILLION STEEL SOLD IN YEAR) TO THE ATMOSPHERE OF THE MAIN METALLURGICAL INDUSTRIES IN THE USSR

In the USSR in the 50s. for the first time in the world, a method of continuous casting of steel was developed, which sharply reduces the loss of metal in the production process. In 1986, this method was poured in the USSR 14% of the steel being smelted, in Japan - 92.7, Germany - 84.6, Yuzh. Korea-71.19, USA-53.4%. Mn. countries, including Japan, Germany, and others, completely abandoned the environmentally harmful open-hearth production of steel; main methods of obtaining steel in the capitalist. countries - oxygen-converter and electric steelmaking. In the USSR it means quantity of steel is produced by the open-hearth method.

In the USSR in 1986, 161 million tons of steel were produced, of which 112 million tons of finished rolled products were obtained; t. arr., the loss of metal is 49 million tons (30.4%). In the US, the same losses amount to 18.4%, Germany - 9.4%, South. Korea-1%. Return (%) of metals for reuse (metal recycling) is estimated on average in the world: Al 11.7, Cu 40.9, Au 15.9, Fe 27.9, Pb 40, Hg 20.6, Ni 19.1 , Ag 47.2, Sn 20.4, Zn 27.

Main ways of development and improvement of metallurgy - the integrated use of raw materials, reducing the consumption of raw materials, energy costs and metal consumption per unit of metal products, ensuring the growth of rolled ferrous metals without increasing their production, the creation of environmentally friendly technologies. processes.

Reducing the number of waste to a minimum (non-waste production) can not be. carried out within the limits of only metallurgical. industries, but requires intersectoral cooperation (closed production) and a new concept of organizing production - "processes to raw materials" (i.e., to places rich inminerals, etc. nature. resources) in contrast to the practice currently used in the USSR - "raw materials for processes". For the first time in ecology, the concept of organizing production from production was expressed by Academician A. E. Fersman in 1932. The transition to such production (processes to raw materials) will increase the integrated use of raw materials and production waste (reproduction of raw materials), ensure the recycling of metals , create metallic materials, taking into account resource saving and the prevalence of metals in nature, to organize closed technol. (chemical-metallurgical) complexes in regions with a high concentration of deposits of various technological orientations (for example, the Kola Peninsula, the Norilsk region). Within the limits of closed production, m. the tasks of providing production with raw materials, structural materials were solved and protection was provided

Introduction

In my opinion, the topic under consideration is relevant, since metallurgy is the largest basic sector of industrial production in Ukraine, which, together with other sectors, determined the general specialization of the country's economy. Donetsk region occupies a leading position in terms of the number and scale of metallurgical plants in Ukraine. Rolled metal produced at the steel mills of the Donetsk region is widely used in mechanical engineering, transport and in all industries without exception, withstands fierce competition from plastics, ceramics, composites, and other modern materials. The metallurgical industry is an industry that brings Ukraine to the world market with fairly high rates and keeps it within the top ten world metal producers. However, as in any other industrial sector, metallurgy has its own development problems that require a speedy solution.

This control work is intended to get acquainted with the metallurgical industry, its essence and significance in Ukraine and the Donetsk region in particular, to consider the crisis situation in the metallurgy market in the period 2007-2009. The objectives of this control work is to identify the main problems and identify ways to solve them in the metallurgy of the Donetsk region and Ukraine as a whole at the state level, as well as its trends further development. Test based on data taken from periodicals and online sources 2007-2012. The work analyzed the statistical data of recent years, and also conducted comparative analysis old indicators with new ones.

The work consists of 4 sections, each of which contains information that reveals in a more complete form the essence of the proposed topic.

Metallurgical industry

The concept of metallurgy and its tasks

METALLURGY - the field of science and technology, covering the processes of obtaining metals from ores or other substances, changes in the chemical composition, structure and properties of metal alloys. Distinguish between pyrometallurgy and hydrometallurgy. It is also used for the production of non-metallic materials, including semiconductors.

Study of the structure and physico-chemical properties of metal and oxide melts and solid solutions, development of the theory of the condensed state of matter;

Study of thermodynamics, kinetics and mechanism of metallurgical reactions;

Development of scientific and technical and economic foundations for the integrated use of polymetallic mineral raw materials and man-made waste with the solution of environmental problems;

Development of the theory of the foundations of pyrometallurgical, electrothermal, hydrometallurgical and gas-phase processes for the production of metals, alloys, metal powders and composite materials and coatings. (5)

The metallurgy of Ukraine is the basic branch of the national economy of Ukraine, provides more than 25% of the industrial production of the state (96,955.5 million hryvnias in 2005), provides about 40% of foreign exchange earnings to Ukraine and more than 10% of revenues to the state budget of Ukraine. In global production ferrous metallurgy the share of Ukraine, according to the International Iron and Steel Institute, is 7.4% (2007). Metallurgy of Ukraine is the enterprises and organizations of the mining and metallurgical complex, which unites not only enterprises of ferrous and non-ferrous metallurgy, but also mining and processing plants, ferroalloy plants, processing plants, coking plants, enterprises producing metal products. (eight)

The metallurgical industry is one of the largest industries of any large state. It includes the extraction and processing of ore, the production and enrichment of metals, the production of alloys from them. Ukraine has significant reserves of various metal ores: ferrous (iron, manganese, chromium, titanium and vanadium), non-ferrous (aluminum, zinc and lead) and precious (silver, gold and platinum) metals. (9)

The metallurgical complex of Ukraine is a well-functioning system of interacting enterprises for the extraction of raw materials, plants for its enrichment and metallurgical plants, occupying an area of tens of thousands of square kilometers. In total, the metallurgical complex has about 400 large and medium-sized ferrous and non-ferrous metallurgy enterprises located in many regions of Ukraine. (9)

Ukraine is one of the leading countries producing ferrous metals in the world and ranks 7th in terms of steel production and 3rd in terms of exports of metal products. Part of the products produced by metallurgical enterprises is 30% of the total industrial production and accounts for 42% of Ukraine's total exports. Over 80% of metal products are exported to Europe, Asia, the Middle East, South America. (eight)

The essence and significance of the metallurgical complex

The metallurgical complex includes enterprises of ferrous and non-ferrous metallurgy, covering all stages of technological processes: from the extraction and enrichment of raw materials to the production of finished products in the form of ferrous and non-ferrous metals, as well as their alloys. The metallurgical complex is a combination of the following technological processes:

Extraction and preparation of raw materials for processing (extraction, enrichment, agglomeration, obtaining the necessary concentrates, etc.);

Metallurgical processing - the main technological process for producing cast iron, steel, rolled ferrous and non-ferrous metals, pipes, etc.;

Alloy production;

Coke production;

Utilization of waste from the main production and obtaining secondary products from them.

The main type of technological connections and form public organization production in the industry is a combination. Therefore, the leading type of metallurgical enterprises are plants. Depending on the combination of these technological processes, the following types of production in the metallurgical complex are distinguished:

Complete cycle plants, in which all the above-mentioned stages of the technological process operate simultaneously;

Partial cycle plants are enterprises in which not all stages of the technological process are carried out (mining and processing of ore, production of steel and rolled products or iron and rolled products separately). Enterprises of an incomplete cycle ("small metallurgy") are called processing enterprises.

Combines where ore is mined and beneficiated are called mining and processing plants (GOK).

The metallurgical complex is the basis of the industry. Ferrous metals are called the bread of industry. Ferrous and non-ferrous metals are widely used in mechanical engineering, construction, transport and all sectors of the national economy without exception, withstanding fierce competition from plastics, ceramics and other modern materials. But in contrast to the recent past, now the level of production of pig iron, steel and rolled products does not judge the economic power of the country.

Exceptionally large complex and district-forming significance of the metallurgical complex in the territorial structure of the economy of Ukraine. It plays a significant role in the international division of labor. The share of base metals and products is 30% of Ukraine's exports. (6) And from the point of view of international demand, it is necessary to constantly improve the quality of metal products, ensuring their competitiveness in a very demanding world market, increase the share of electric steel and ferroalloys, pipes, etc.

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COURSEWORK

Proi organizationproduction at the enterprise of the industrymetallurgy

Introduction

OJSC NLMK is one of the largest metallurgical plants in the world. It is the third largest steel producer in Russia.

The plant is located in the center of the European part of Russia, in the city of Lipetsk, not far from the largest iron ore basin of the Kursk magnetic anomaly.

NLMK is an enterprise of a full metallurgical cycle. The production facilities include mining and processing, sintering, coke production, blast furnace production, steelmaking, production of hot-rolled and cold-rolled steel, rolled products with zinc and polymer coatings, as well as oxygen production.

This course work is devoted to oxygen production at NLMK OJSC.

In the first part of the work, the production structure of the production unit (Oxygen Shop) is described in detail. The role and importance of the oxygen shop in the overall production process of NLMK. The use of oxygen and air separation products in metallurgical processes, as well as the description of the technological chain of the production process in the oxygen shop. air separation process.

The second part deals with the organization of the production process in the production unit: Energy production of OJSC NLMK. Management structure of the oxygen shop.

The third part of the work describes the calculation of the production capacity of the workshop.

1. Production structureproduction unit

1.1 Oxygen shop JSC « NLMK"

The oxygen shop is a production and structural unit of NLMK's energy production. As part of the oxygen production, there are two compressor stations to provide the workshops of the plant with compressed and dried compressed air.

The oxygen shop has the right to carry out activities for:

1. Operation of production for the receipt, processing, storage and use of air separation products.

2. Installation and commissioning of metallurgical and coke-chemical industries and facilities.

3. Repair of units and equipment of metallurgical and coke-chemical facilities.

4. Operation of explosive production facilities.

5. Implementation of hazardous waste management activities.

6. Environmental activities (utilization, storage, movement, placement, burial, destruction of industrial and other wastes).

The composition of oxygen production includes:

Oxygen station No. 1;

Oxygen station No. 2;

Section of external networks and compressor stations (central compressor station and station of dried air district AGP).

Currently, the workshop is completing technical re-equipment. Almost all equipment is new, high-performance, computer-controlled. Specialists with higher education work at air separation plants. All information about the operation of the block is displayed on computers.

Air from the atmosphere, through filters, is sucked in by compressors and compressed to 6 kgf/cm 2 , with subsequent supply to the ASU to obtain separation products (SDP), nitrogen, oxygen, argon, a mixture of inert gases (krypton-xenon concentrate), neon-helium mixture ( technical neon), and further are served to consumers of PRV.

Technical oxygen with a purity of 99.5% pressure up to 1.9 MPa is used in steelmaking in oxygen-converter shops (BOF).

Oxygen technological purity 95% with a pressure of 400 mm of water. st - for the intensification of blast-furnace iron production, enrichment of blast-furnace blast with oxygen up to 30-40%, allows improving the heat balance of melting, increasing the productivity of furnaces.

Nitrogen 99.999% is consumed by sheet-rolling shops (LPTs-2; LPTs-3; LPP; LPTs-5), refractory shop, KKTs-1, KKTs-2, gas shop.

Nitrogen 98% - for purging intercone spaces in the blast furnace process (BP-6), at USTC (KHP), KKTs-1 and KKTs-2.

Argon - for blowing in the process of pouring special high-quality steel grades to remove dissolved gases (KKTs-1, KKTs-2). Argon is released to the side in liquid and gaseous form.

Oxygen production provides workshops and production plants with oxygen for autogenous needs and compressed air. Liquid and gaseous oxygen, krypton-xenon concentrate, neon-helium mixture are released to the side.

1.2 The role and importance of the oxygen shop in the overall production process of OJSC « NLMK. Application of oxygen and air separation products in metallurgical processes

The use of oxygen for the intensification of technological processes has recently become widespread. It is one of the most important stimulators of technical progress in ferrous and non-ferrous metallurgy, chemical and other industries, where technology is based on physical and chemical processes oxidation and reduction.

At present, the smelting of iron and steel is carried out only with the use of oxygen.

In recent years, Russian metallurgists have accumulated extensive experience in the development and industrial development of methods for intensifying blast-furnace, converter and open-hearth processes with oxygen, steel smelting in electric furnaces and non-ferrous metal smelting.

The use of oxygen can significantly improve the technical and economic performance of metallurgical processes. However, the role of oxygen is reduced not only to the intensification of metallurgical processes. The use of oxygen has an impact on the structure of metallurgical industries, on their relations with each other and with service and related industries, and from this point of view it is a qualitatively new factor in technical progress in metallurgy.

The raw material for producing oxygen in industry is atmospheric air, which contains oxygen, nitrogen, argon, krypton and other gases in a chemically unbound state.

The separation of oxygen from a mixture of gases (air) requires much less energy than when it is obtained from a substance containing it in a chemically bound state, for example, water.

The industrial method of separating oxygen and other components from the air is carried out in the following two stages:

1. Air cooling and its subsequent liquefaction.

2. Separation of liquid air into nitrogen, oxygen and other gases in special distillation chambers.

Oxygen is a powerful intensifier of metallurgical production. In terms of the amount of oxygen consumed, ferrous metallurgy ranks first. Oxygen is used in the smelting of iron and steel, as well as for stripping and cutting ingots in steel production.

In blast furnaces, when iron is smelted, oxygen is enriched in the air blown into the furnace to burn the loaded fuel. For example, a relatively small enrichment of blast air with oxygen (up to 25-28% O 2) makes it possible to increase the productivity of a blast furnace by 15-20% when smelting blast-furnace ferroalloys (ferrosilicon and ferromanganese), use poorer ores and reduce fuel consumption when smelting special grades cast iron. The blast furnace requires very large amounts of oxygen - 50,000-100,000 m 3 /h or more.

The use of oxygen in combination with natural gas in the blast-furnace process is especially effective. In this case, with a content of 30-35% oxygen in the blast, the productivity of the furnace increases by 30%, and the specific consumption of coke decreases by 25-40°. Modern giant blast furnaces with a capacity of 2700-3000 m 3 operate with the use of oxygen.

The use of oxygen in converter melting makes it possible to obtain cheaper converter steel in quality equivalent to open-hearth steel. In this regard, powerful converter shops of a new type have been built at a number of large metallurgical plants in Russia. Steel is obtained in converters by blowing liquid iron with pure oxygen introduced from above through the neck.

The main advantage of the converter method is the high melting speed, and the melting speed is one of the fundamental problems of metallurgy. Therefore, the oxygen converter makes it possible to sharply increase steel production at lower capital and operating costs.

The cost of building a shop with powerful converters is 35% lower than the cost of building an open-hearth shop. Converter production puts forward increased requirements for oxygen concentration, which must be at least 99.5% O 2 . The use of pure oxygen makes it possible to drastically reduce the nitrogen content in steel, as a result of which the quality of converter steel is not inferior to open-hearth steel, and it surpasses open-hearth steel in malleability, weldability and ductility.

Oxygen in electric steelmaking is used in almost all plants that have electric steelmaking shops. With the use of oxygen, the predominant part of the electric steel is smelted. The use of oxygen is especially effective in the production of stainless and other high-alloy steels. When the molten bath is blown with oxygen, higher temperatures are reached, the process of carbon oxidation is significantly accelerated, and the required carbon content in stainless steel is achieved.

For gas welding, oxygen is mixed with a combustible gas, such as acetylene, propane, to intensify the process of gas combustion and obtain a flame with a high temperature, which is required for the rapid melting of metal at the welding site. Oxygen can be used to cut steel ingots, ingots and plates up to 1500 mm thick or more. Acetylene, propane, natural gas, kerosene vapor, hydrogen, coke oven gas, etc. are used as fuel for cutting.

In recent years, for fire cleaning and cutting of metal with oxygen, special machines have been used that are built into the rolled conveyor.

When melting and pouring metals in an inert atmosphere, there are great prospects for improving the quality of the metal (especially steel of special grades). It is also very effective to purge with argon before the release of steel from the electric furnace to remove dissolved gases. Argon consumption is about 1 m 3 /t. Argon is also used in the smelting of titanium, zirconium, as well as in the welding of aluminum, titanium and other non-ferrous metals. The extraction of argon in large quantities simultaneously with the extraction of oxygen from the air at the oxygen stations of metallurgical plants makes it possible to obtain it at a relatively low cost and widely introduce it into metallurgical processes.

In addition to the listed industries, oxygen is used in the mining industry for fire drilling of wells, in the cement, pulp and paper industries, medicine, aviation, etc.

This brief overview shows that there are the widest applications of oxygen in various technological processes. The requirements for oxygen plants, both in terms of the quantity of products produced and their quality (concentration, impurity content, humidity), are very diverse. In addition, the individual processes require different pressures and different flow schedules. For example, in the blast-furnace process - continuous supply, in the converter and open-hearth - periodic.

It is also necessary, in most cases, to supply oxygen for considerable distances from the oxygen shop to almost the entire plant, and sometimes to other enterprises.

Increased air pollution in the area of metallurgical plants causes additional difficulties associated with thorough cleaning of the processed air. However, the oxygen industry has been around for almost 90 years. During this time, oxygen apparatuses and machines have received a high technical development.

1.3 Technological chain of the production process in the oxygen shop. Air separation process

Atmospheric air is a mixture of nitrogen, oxygen, argon and rare gases that are not chemically related. Approximately, air can be considered as a mixture of only nitrogen and oxygen, since argon and rare gases contain less than 1%, in this case it is assumed (rounded) that the volume content of nitrogen in the air is 79% and oxygen is 21%.

The separation of air into oxygen and nitrogen is a rather difficult technical task, especially if the air is in a gaseous state. This process is facilitated if the air is first converted into a liquid state by compression in compressors, expansion and cooling, and then it is separated into its component parts using the difference in the boiling points of liquid oxygen and nitrogen. Liquid nitrogen under atmospheric pressure boils at a temperature of - 195.8°C, and liquid oxygen at - 182.97°C. If liquid air is gradually evaporated, then at first nitrogen, which has a lower boiling point, will mainly evaporate; as nitrogen escapes, the liquid is enriched with oxygen. By repeating the process many times, it is possible to achieve the desired degree of separation of air into nitrogen and oxygen of the required purity. The process of separating liquid mixtures into their component parts by repeated evaporation of the liquid is called rectification.

Therefore, the described method of obtaining oxygen is based on the liquefaction of air by cooling it to a very low temperature and subsequent separation into oxygen and nitrogen by the rectification method. That's why this way obtaining oxygen is called deep cooling.

At present, obtaining oxygen from air by deep cooling is the most economical, as a result of which this method has become widespread industrially. Deep cooling and rectification of air can produce virtually any amount of oxygen and nitrogen at a relatively low cost. The consumption of electricity to obtain 1 m 3 of oxygen is 0.4 - 1.6 kW * h (1.44 * 10 6 -5.76 * 10 6 J) depending on the performance and technological scheme installation.

Technological process air separation consists of the following main stages:

1. air purification from dust and mechanical impurities;

2. air compression in compressors;

3. purification of compressed air from carbon dioxide;

4. drying compressed air and cleaning it from hydrocarbons;

5. liquefaction and rectification of air for separation into oxygen, nitrogen, extraction of rare gases - argon and krypton-xenon;

6. accumulation of the obtained gaseous oxygen in a gas tank or liquid oxygen in a storage tank;

7. filling cylinders with gaseous compressed oxygen, supplying compressed oxygen to the consumer through a gas pipeline or filling transport tanks and cisterns with liquid oxygen from stationary tanks and cisterns;

8. purification of rare gases from oxygen and nitrogen, bringing their composition to the requirements of GOST, and filling cylinders with rare gases (Appendix 1).

Technological schemes and designs of air separation plants are determined by the requirements for productivity, concentration of separation products, and operating conditions.

According to their technological schemes, the installations differ:

* method of obtaining cold (refrigeration cycle);

* methods of air purification from carbon dioxide and moisture;

* rectification scheme.

Air purification from mechanical impurities, necessary to remove dust and random solid particles (mechanical impurities), is carried out using devices for primary air treatment - air intakes and filters.

The operation of air separation plants requires compressed air, which is not only a production raw material, but also a source of cold, which is necessary for liquefying gases and compensating for cold losses in the plant. The cooling effect of compressed air is manifested in the process of its throttling (deep cooling and liquefaction of gases). Turbochargers are used to compress air. The main requirements for compressors supplying air to air separation plants are their reliability and high efficiency. It is known that high-capacity centrifugal compressors have a higher efficiency compared to low-capacity machines, and the cost of 1 m 3 oxygen depends on the economy of operation air compressor. Based on this, it is more profitable to complete air separation plants with the most powerful machines possible.

Removal of water vapor from the air is a mandatory process of air treatment before it enters the separation apparatus. In oxygen plants, the following air drying methods are used: chemical (moisture is absorbed by solid caustic soda); adsorption (moisture from the air is absorbed by adsorbents - alumogel, silica gel or zeolite); freezing moisture by cooling the air to 30 - 40 0 C in switching heat exchangers , where water vapor falls in the form of water or ice on the working surface of the apparatus; freezing of moisture together with carbon dioxide during air cooling in regenerators.

Purification of air from carbon dioxide (CO 2). Carbon dioxide and water vapor entering the separating apparatus precipitate and freeze when low temperatures. Clogging of the distillation column with solid carbon dioxide disrupts the operation of the installation, as a result of which the separation apparatus is periodically stopped for heating.

In the production of oxygen, chemical and physical methods are used to purify the air from carbon dioxide. Currently, air separation plants are equipped with blocks of complex air purification with highly efficient adsorbents - zeolites. Physical purification (in regenerators) is carried out by cooling the air to approximately -170 0 C. At this temperature, carbon dioxide almost completely turns into a solid state and lingers in the regenerator nozzle.

The main method for obtaining oxygen, nitrogen, argon and other products of air separation is the method of deep air cooling followed by rectification (separation) in column-type apparatuses. For deep cooling, the property of compressed gases to lower the temperature during expansion is used.

Reducing the pressure of compressed air per atmosphere with a sharp expansion (throttling) will be accompanied by a drop in temperature. The temperature of the gas decreases even more effectively when it expands and does work. A machine based on this principle is called an expander. If compressed gas is directed into the cylinder, then when the gas expands, the piston moves and work is done, and the gas itself cools sharply. The gas can also be cooled in a turboexpander, where the compressed gas rotates the impeller. Modern air separation plants are built using both the throttling effect and air expansion in turbo expanders (Appendix 2).

Argon is the cheapest rare gas, as it is contained in the air in much larger quantities than other rare gases. Therefore, the production of argon in air-separating apparatuses is continuously increasing. Getting pure argon includes three stages. First, in the air separation apparatus, along with oxygen or nitrogen, a nitrogen-argon-oxygen mixture is obtained, the so-called crude argon, with a content of 65 to 95% argon. Then this mixture is subjected to catalytic purification from oxygen when the latter is bound by hydrogen to obtain a mixture of nitrogen and argon. The third stage of the process is to separate the nitrogen-argon mixture into pure argon, which is recovered as a final product, and nitrogen, which is released into the atmosphere. The technological process of obtaining krypton and xenon includes three stages.

1. Obtaining primary (poor) krypton-xenon concentrate containing 0.1-0.2% krypton and xenon in total.

2. Enrichment of the primary concentrate and obtaining from it technical krypton with a content of up to 99% of krypton and xenon (in total) or a krypton-xenon mixture with a content of up to 95% of krypton and at least 5% of xenon.

3. After the ASU, nitrogen and oxygen are supplied to the oxygen and nitrogen compressors. Oxygen is compressed to a pressure of P = 30 kgf/cm 2 and supplied to oxygen distribution points, and then to the plant's network: to the converter shops of KKTs-1 and KKTs-2, sheet-rolling production, blast furnace production, electric steelmaking shop, steel-bearing shop, repair shops mechanical equipment, treatment facilities, production complex household appliances, coke production.

The main consumers of nitrogen are: sheet-rolling production (an ANO continuous annealing unit, AGC hot-dip galvanizing unit, bell-type furnaces, methodical furnaces), converter production (desulfurization department), coke production (for dry coke quenching plants), carbide - carbon black shop, production of complex household equipment, blast-furnace production (charging apparatus).

The main consumers of argon are converter shops (combined blowing of steel), production of dynamo steel, production of complex household appliances, mechanical repair shop, shaped and foundry shop.

2. Organization of the production process in the production department: Energy production OJSC « NLMK. Management Structure of the Oxygen Shop

Power production (EP) is a structural subdivision of NLMK OJSC and is directly subordinate to the First Vice President - CEO. The energy production is headed by the head of the energy production.

The Energy Production includes the following structural subdivisions of NLMK: Combined Heat and Power Plant (CHPP), Oxygen Shop, Power Supply Center (TsES), Gas Shop, Thermal Power Shop (TPS), Water Supply Shop (CWS), Process Dispatching Shop (TsTD), Energy Repair Shop workshop (EnRC), Electrical repair workshop (ElRC).

The power production management structure is developed by the head of the power production, signed by the head of the Department of Labor and Personnel Organization (UOTiP), coordinated by the HR director and approved by the first vice president - general director.

The staffing table of the Energy Production is developed by the Head of the Energy Production, signed by the Head of the Department of Health and Safety, approved by the Director for Personnel and General Affairs.

In its activities, the Energy Production is guided by the following documents:

ѕ legislative and regulatory acts Russian Federation;

* the Labor Code of the Russian Federation;

* Rules of the internal labor regulations of NLMK employees;

ѕ NLMK's collective agreement;

* the Articles of Association of OJSC NLMK;

ѕ resolutions of the General Meeting of Shareholders, the Board of Directors, the Management Board of NLMK;

* orders, orders and instructions of NLMK's management;

ѕ orders and instructions of the management of the Energy Production;

* normative documents of the Quality Management System of NLMK;

* Regulatory documents of the Control System environment OJSC NLMK;

* regulatory documents that define the requirements for the design and operation of electrical installations;

* Regulations on the Occupational Health and Safety Management System at NLMK;

* Regulations on the Procedure for Investigation and Recording of Occupational Accidents at NLMK;

ѕ other documents regulating the activities of the personnel of the Energy Production.

The structure of the Energy Production of the management structure of the Oxygen Shop includes the head of the shop, to whom the following are directly subordinated:

* head of the repair preparation service;

* head of oxygen station No. 1;

ѕ deputy shop manager (for technology);

* head of oxygen station No. 2;

ѕ head of the service for the operation of el. equipment;

* chief specialist (for technical re-equipment) (Appendix 3).

Responsibilities of the head of the repair preparation service include:

ѕ organization and control over the operation of the shop equipment;

ѕ planning, organization and control of repairs and activities for the technical re-equipment of equipment;

ѕ control of the logistics of repairs. Documentary support of the process;

* development of measures to eliminate damage and eliminate the emergency state of equipment;

ѕ development, execution, coordination of schedules of planned work and technical specifications for repair and maintenance equipment.

Subordinate to the head of the repair preparation service are: the foreman of the production preparation site, who supervises the work of locksmiths - repairmen, electric and gas welders, crane operators, tractor drivers and storekeepers, and an equipment configuration engineer.

The duties of the head of oxygen station No. 1 include: management and direct participation in the production process of air separation products and organization of storage and distribution of air separation products. In his subordination are: the head of the section (rare gases), who manages the work of the ASU apparatchiks, as well as the ASU specialists and technical supervision engineers and a process engineer.

The duties of the head of the workshop (in technology) include: management of the production, economic and technological activities of the workshop (site); introduction of advanced domestic and foreign experience design and production technology of similar products; coordination of work of masters and workshop services; accounting, submission of established reporting; selection of personnel of workers and employees, their placement and expedient use; advanced training of workers and employees of the shop; monitoring compliance by employees with the rules and regulations of labor protection and safety, as well as compliance with production technology. His subordinates are: chief specialists, senior foremen, head of the compressor station service.

The duties of the head of the service for the operation of electrical equipment include: supervising the operation of equipment according to the approved scheme, schedule and assigned data; keeping records of the main equipment and issuing permits for its operation; control over compliance by employees of the electrical equipment operation service with the requirements of operating guidelines; analysis of technical and economic performance of facilities, development of measures to eliminate violations; coordination in accordance with the established procedure of excavation and construction work on the serviced site, in the area where the facilities of the electrical equipment operation service are located; organization of supervision over the safety of structures and devices, etc.

The duties of managers and specialists of the Energy Production are defined in the relevant job descriptions developed in the prescribed manner.

3. Production capacity calculation

The most important qualitative characteristic of an industrial enterprise, which evaluates its production and technical potential, that is, the maximum possible annual production of products of a given quality, assortment, range, subject to the full use of the fund of operating time and passport equipment performance, taking into account the use of advanced technology and advanced methods of organization and management production.

The production capacity of the enterprise in market conditions is the most important means of flexible production response to changes in market demand in the short term. The difference between the value of production capacity and the actual volume of production and sales of products is a real reserve for prompt response to an increase in demand for these products.

When developing strategic plans for the development of an enterprise, indicators of the current production capacity are taken into account, taking into account its possible changes in the long term. Production capacity serves as the basis, the basis for the development of planned indicators for the production program of enterprises with continuous and in-line production, producing a limited range of products that, as a rule, have homogeneous consumer properties. In discrete industries, characterized by the production of a wide range of qualitatively homogeneous products, the calculation of production capacity is carried out with mandatory accounting. And more often on the basis of such indicators of the production program as the planned product range and its structure. In accordance with this, various methods for calculating the production capacity of such enterprises are used. Both in the first (continuous production processes) and in the second (discrete production) cases, the production capacity of an enterprise is determined by the capacity of the leading redistribution. The leading redistribution is considered: when calculating the capacity of the enterprise as a whole - the workshop (production); when calculating the capacity of a workshop - a section or a separate unit (apparatus) where the main technological operations for the production of products are performed and in which the predominant part of the equipment is concentrated in terms of cost.

The production capacity of an enterprise (workshop, section, unit) is the maximum possible amount of products (services) that can be produced in a certain period (usually a year) with the most efficient use production assets, the use of progressive technology and advanced methods of organizing labor production.

The calendar time is understood as the full calendar duration of the corresponding period (for example, a year - 365 days, etc.).

Rated time refers to the time during which the equipment is used in production. This time is also called production, working, regime. Rated time is the period during which the equipment was supposed to work. However, in practice, this is not always ensured due to the occurrence, as a rule, of unforeseen current downtime of equipment.

Current downtime is a long interruption in the operation of the equipment during the nominal time, caused by technical or organizational reasons.

The actual operating time of the unit is the period during which the corresponding technological process is carried out on the unit, i.e. when the equipment actually works. It is also called effective or useful.

A preventive maintenance system (PPR) is a set of organizational and technical measures for the care, supervision, maintenance and repair of equipment, carried out preventively, according to a pre-planned plan to prevent unexpected equipment failure and maintain it in constant operational readiness.

Overhaul of the unit provides for its complete development, flaw detection, restoration or replacement of parts with subsequent assembly, adjustment, testing.

The main units of the shop are: AKt-30 st. No. 1; ACT-30 Art. No. 2; VRU No. 4.

The annual fund of the actual operating time of the unit is calculated by the formula:

t \u003d (KV - VD - PD - KR - PPR) * DS * CHS *;

* KV - calendar time, days;

* VD - days off;

* PD - holidays;

* KR - overhaul, days;

ѕ PPR - scheduled preventive maintenance, days;

* ES - number of shifts, day;

* DS - shift duration, hour;

* TP - current downtime as a percentage of the nominal time.

KV = 365; VD = 0; PD = 0; CR = 12; PPR = 23; CHS = 3; DS = 8.

t = (365 - 12 - 23) * 8 * 3 * 0.967 = 7658.63 hours.

Production capacity is calculated by the formula:

M \u003d t * a * H;

* t - annual fund of the actual operating time of the unit;

* a - the number of units of the same type installed in the shop;

* H - hourly rate of performance according to the passport.

M = 7658.3 * 3 * 40 = 919035 tons / year.

Below (Figure 2) is a time schedule of the production process of the oxygen shop.

Figure 2 - Schedule of the production process of the oxygen shop

Conclusion

The use of oxygen for the intensification of technological processes is currently widespread. It is one of the most important stimulators of technical progress in ferrous and non-ferrous metallurgy, chemical and other industries, where technology is based on physical and chemical processes of oxidation and reduction.

In the course of this course work, the production structure of the production unit, namely, the Oxygen Shop of NLMK OJSC was described, the scope of oxygen and air separation products in metallurgical processes was considered in detail. In addition, the technological chain of the production process in the oxygen shop (air separation process) was described, the organization of the production process in the production unit of the shop was characterized, and the production capacity was calculated and the schedule of the production process of the shop was built using the Gantt Project program.

List of used literature

1. Regulations on the oxygen shop P - 023 - 000 - 2011, Lipetsk, NLMK OJSC.

2. Analysis of the economic activity of the enterprise: Textbook 5th ed., Revised. and additional (" Higher education”) (neck) / Savitskaya G.V. - 2011. 536 p.

3. Economics of the enterprise - M.: INFRA - M / Sklyarenko V.K., Prudnikov V.M., - 2006. 528 p.

4. Electronic resource: http://www.nlmk.ru

5. "Production of oxygen"; D.L. Glizmanenko.; M. Ed. "Chemistry". 1974 - 225 p.

6. "Installation of oxygen stations"; A.I. Mikhalchenko, V.I. Khudyakov; 1986 - 185 p.

7. "Separation of air by the method of deep cooling"; ed. IN AND. Epifanova. M. Mashinostroenie 1973 - 146 p.

8. “Technical and economic bases of design in ferrous metallurgy. Oxygen production”.; Tutorial diploma design. Moscow, 1973 - 99 p.

9. Electronic resource: http://soft. GanttProject.html

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Ferrous metallurgy

An industry with its own nuances. It is important to understand that not only the metal is important for it, but also mining with subsequent processing.

Highlight its important features:

more than half of the products serve as the basis for the entire engineering industry of the country;
a quarter of the products are used in the field of creating structures with increased load capacity.

Ferrous metallurgy is production, coal coking, the secondary limit of alloys, the production of refractories and much more. The enterprises included in the ferrous metallurgy are of the greatest importance and, in fact, are the basis of the industry of the entire state as a whole.

The main thing is that around them there are production facilities for the processing of various wastes, especially after the smelting of cast iron. Metal-intensive machine building and electric power production are considered the most frequent satellite of ferrous metallurgy. This industry has great prospects for the future.

Ferrous metallurgy centers in Russia

First of all, it should be remembered that Russia has always been and is the absolute leader in terms of the density of ferrous metal production. And this championship without the right to transfer to other states. Our country is confidently holding its positions here.

The leading plants are, in fact, metallurgical and energy-chemical plants. Let's name the most important centers of ferrous metallurgy in Russia:

Ural with iron and ore mining;
Kuzbass with coal mining;
Novokuznetsk;
Locations of KMA;
Cherepovets.

The metallurgical map of the country is structurally divided into three main groups. They are studied at school and are the basic knowledge of modern cultured person. It:

Ural;
Siberia;
Central part.

Ural Metallurgical Base

It is she who is the main and, perhaps, the most powerful in terms of European and world indicators. It has a high concentration of production.

The city of Magnitogorsk is of paramount importance in its history. There is a famous metallurgical plant. This is the oldest and hottest "heart" of ferrous metallurgy.

It produces:

53% of all cast iron;
57% of all steel;
53% of ferrous metals from all indicators that were produced in the former USSR.

Such production facilities are located near raw materials (Ural, Norilsk) and energy (Kuzbass, Eastern Siberia). Now the Ural metallurgy is in the process of modernization and further development.

Central metallurgical base

It includes factories of cyclical production. Represented in the cities: Cherepovets, Lipetsk, Tula and Stary Oskol. This base is formed by iron ore reserves. They are located at a depth of up to 800 meters, which is a shallow depth.

The Oskol Electrometallurgical Plant was launched and is successfully operating. It introduced an avant-garde method without a blast-furnace metallurgical process.

Siberian metallurgical base

Perhaps she has one feature: she is the "youngest" of the existing bases today. It began its formation during the USSR period. Approximately one fifth of the total volume of raw materials for pig iron is produced in Siberia.

The Siberian base is a plant in Kuznetsk and a plant in Novokuznetsk. It is Novokuznetsk that is considered the capital of Siberian metallurgy and the leader in terms of production quality.

Metallurgical plants and the largest plants in Russia

The most powerful full cycle centers are: Magnitogorsk, Chelyabinsk, Nizhny Tagil, Beloretsk, Ashinsky, Chusovskoy, Oskolsky and a number of others. All of them have great prospects for development. Their geography, without exaggeration, is huge.

Non-ferrous metallurgy

This area is busy with the development and enrichment of ores, participating in their high-quality smelting. According to its characteristics and purpose, it is divided into categories: heavy, light and valuable. Its copper-smelting centers are almost closed cities, with their own infrastructure and life.

The main areas of non-ferrous metallurgy in Russia

The opening of such areas depends entirely on: the economy, environmentalists, raw materials. This is the Urals, which includes factories in Krasnouralsk, Kirovgrad and Mednogorsk, which are always built next to the production. This improves the quality of workmanship and the turnover of raw materials.

Development of metallurgy in Russia

Development is characterized by high rates and volumes. Therefore, huge Russia is in the lead and is constantly increasing its exports. Our country produces: 6% iron, 12% aluminum, 22% nickel and 28% titanium. Read more thisit is reasonable to look at the information in the tables of productions presented below.

Map of metallurgy in Russia

For convenience and clarity, the issue of special maps and atlases has been arranged. They can be viewed and ordered online. They are very colorful and comfortable. The main centers with all divisions are indicated there in detail: copper smelters, places for the extraction of ore and non-ferrous metals, and much more.

Below are maps of ferrous and non-ferrous metallurgy in Russia.

Factors of location of metallurgical plants in Russia

The fundamental factors influencing the location of plants in the country are literally the following:

raw materials;
fuel;
consumption (this is a detailed table of raw materials, fuel, small and large roads).

Conclusion

Now we know: there is a clear division into ferrous and non-ferrous metallurgy. This distribution by extraction, enrichment and smelting depends directly on the main components: raw materials, fuel and consumption. Our country is the European leader in this field. The three main geographical "pillars" on which it stands are: the Center, the Urals and Siberia.