Since there is little hope that the construction of ferroalloys shop No. 3 at the Chusovoi Metallurgical Plant will be completed anytime soon, it is important to focus on the rebuilding of ferroalloys shop No. 2. Shop No. 2, which has been in operation since 1964, is the final stage in the vanadium production cycle at the plant and yields ferrovanadium as the commercial product.The reconstmctsion program for the existing shop should be based on the following measures: -bringing shop capacity up to 7500 tons of 38% ferrovanadium per year, to ensure that the shop will be able to process at least the increasing volume of converter slag being formed in production operations at the plant;-increasing the amount of vanadium recovered by 10-12%, with a corresponding increase in the output of ferrovandium; -reinforcing the buildings and installations of the shop, which have been in use since 1964;-expanding the range of vanadium-bearing products made in the shop;-introducing new production processes and modernizing existing equipment; -mass-producing various pieces of equipment. The modernization must be carried out while the shop continues to operate, with no adverse effects on output or performance indices. Thus, the amount of work that must be done in the reconstruction and the complexity of the design changes should be evaluated in several stages. The actual reconstructsion work should also be done in stages.The order of the stages will be determined by the priority assigned to the various objectives, the financial impact, the degree to which the design changes are ready to be implemented, and whether or not the necessary planning and budget documentation has been completed. The optimum sequence for the stages in the reconstructsion program is as follows: conceptualization/setting of objectives; scientific research and experimental design work (preferably done on a competitive basis); design of the rebuilt shop, including determination of the main design features, determination of the composition of the equipment, and evaluation of the cost-effectiveness of the changes; finalization of the investment plans; development of the specifications; construction. This scheme can be modified to speed up the completion of the project, i.e., some of the stages may be executed simultaneously.Proceeding on the basis of the above scheme and an analysis of the means by which it might be implemented, we can identify the following stages and establish the following tentative schedule for reconstruction of the ferroalloys shop at the Chusovoi Metallurgical Plant.First stage: organization of the new section for filtration and leaching of the vanadium pulp, which is intended to eliminate a bottleneck in the production process and will significantly improve the performance indices of the shop in the production of vanadium pentoxide; construction of a section for removing vanadium and manganese from the waste water, in order to solve the main environmental problem facing the plant. One feature of this stage is that work on it was begun bef...
The Chusovoi Metallurgical Plant faces an acute problem in attempting to clean the waste water from its chemicals division, which produces commercial vanadium pentoxide. For example, waste water containing 27 tons of vanadium and 163 tons of manganese was discharged into resevoirs in 1998.The fines levied on the plant just for the vanadium and manganese in the waste water were approximately 132.1 million rubles, which accounts for 87% of the total amount of money paid in penalties for pollution. The profit left after payment of the fines was 23.5 million rubles.The large sums of money being paid because of pollution have created serious difficulties for the plant in meeting its obligations to the federal budget and economic funds, implementing anti-pollution measures, making capital improvements, and resolving social problems.Several projects have been undertaken to alleviate the above situation. However, the lack of the necessary financing has put those projects behind schedule.
The main bottleneck in the chemicals division of the Chusovoi Metallurgical Plant is the leaching and filtration section.There are two main reasons for the problems being encountered in the operation of the section:1) the use of filtration equipment of an old design (drum-type vacuum filters with an internal filtering surface), which consumes a substantial amount of time in replacing the filter cloth while producing a filtrate with excess suspended solids and a filter cake with excess moisture;2) the use of a three-stage leaching system that employs a large number of pieces of equipment -vacuum filters, mixing tanks, collectors, settling tanks, and concentrators -and does not achieve the required performance indices.With the market for ferrovanadium now growing, the leaching and filtration section has become an impediment to increasing product output. This has become especially apparent in the last two years. To resolve the problem, the plant has enlisted the help of specialists from the Vostochnaya Ukraina Scientific-Industrial Association to determine the feasibility of filtering the pulp with a new generation of press filters (chamber-type press filters of type FKMg, with top-suspended slabs). Scientific research on this subject has determined the following: the productivity and number of press filters required; their cyclograms; the possibility of combining the processes of filtration, washing, and leaching of the vanadium and drying of the filter cake in One unit. The results of this work were used to generate initial data for the design of the filtration and leaching section. One of the organizations involved in developing the specifications was the institute Giprostal' (Kharkov, Ukraine) -the lead organization involved in the original design of existing ferroalloys shop No. 2.To reduce capital costs, it was decided to build the new section in the building that currently houses the third roasting furnace after the existing equipment and metal structures have been dismantled and the building has been renovated.The design of the new filtering and leaching section, completed in 2000, provides for the following operations: filtering of the pulp created during water leaching; a first washing with water; sulfuric-acid leaching in the recirculation regime; a second washing with water; drying of the filter cake with air. All of the operations will be performed in one unit in the automatic regime. The plan also entails an eventual increase in production capacity to 30% above the present level. The equipment will be installed in a compact configuration at one level. The facility that houses the existing leaching section will be freed for other uses. In particular, it might be used as the site for a complex that can treat waste water. The work stations will be equipped in accordance with the requirements of the production process and the organization of the various tasks.The new equipment can also be used for other technologies, including a changeover to water leaching. 2000.Chusovoi Metallurgical Plant and the United...
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