Metallurgical Mini Plants
Technologies and Equipment for Micrometallurgical Plant
Tech Area / Field
- MAN-PDM/Plant Design and Maintenance/Manufacturing Technology
8 Project completed
Senior Project Manager
Karabashev S G
All-Russian Scientific Research Institute of Non-Organic Materials named after A. Bochvar / State Center for Condensed Matter Physics of MINATOM, Russia, Moscow
- MISIS (Steel and Alloys), Russia, Moscow
- Universidad del Pais Vasco, Spain, Bilbao\nTU Bergakademie Freiberg, Germany, Freiburg\nTechcom Import-Export GmbH, Germany, Munich
Project summaryMetallurgy (as many other human activities) has being developed through the progressive increasing of the total output, creation of the modern and powerful equipment. But nowadays we are on the dangerous brink of self-annihilation for an environment destruction (in particular, it’s very prominent in industry-developed regions). At the same time increasing of safety characteristics in aerospace and atomic power areas demands specific approaches to developing construction materials for the cited above industries with small production amount. Therefore it might be assumed that period of «giant mania» in metallurgy is being overcame (because of ecological reasons basically). And now metallurgy is on the way to be dispersed in small industrial units. Indeed since 70-th side by side with large-scale metallurgical works «the mini-plants» of a small output have been introduced (annual output is 200-500 thousand tons). Nowadays in the United States of America one forth of the total metallurgical production is produced in the mini-plants.
Taking into account contemporary tendency one can predict the XXI century metallurgy will include micro-metallurgical plants of 3-30 thousand tons per year. Small outcome is stipulated by the actual needs of atomic power industry in specific reactor materials (for example, spring rods for the fixation of the special elements; couple wire; special tubes; etc.). This metal products have a small cross section and small weight per meter. In a number of cases application of high effective materials in nuclear power is restrained (or it is impossible) in the large-scale metallurgical works because of the composition reproduction difficulties and of the treatment conditions. Micro-metallurgy is of the great interest from several points of view. Before it was marked the important and positive influence of «dispersion process» on the ecological state. The energetic point of view is a great importance as well (not less importance is an energy saving indicator). The modern rolling technology assumes that a final product is made from an ingot of 28000 kg weight. Small cross section rolled metal are produced in the process of multy-stage high cogging (stretch), intermediate pre-heating and intermediate thermal treatment with using high-cost equipment. It’s resulted in the decreasing of the coefficient of metal utilization because of scale (oxide), cut of a billet edge, cleaning of the defects, etc. As well as it demands extra working areas and non-effective energy consumption. And it’s not economical problem only but ecological one, as far a substantial heating is disseminated.
It’s known that for the most steel and alloys a casting billet structure is avoided and mechanical properties become optimal under 5…7 times stretch. It is mean that there is no need to use multistage technology (from quality point of view) with super-powerful equipment. That is why elaboration of technology and equipment for micro-metallurgical plant is important, actual and urgent task both for Russia and other developing and developed countries over the world. Besides, from economic point of view micro-metallurgical works have also one advantage: this plant can solve problem of supply distant regions, can eliminate transportation of metal scarp and metal product to these distant regions.
Requirements for micro-metallurgical works:
— production of a small consignments of metal products with wide range of geometrical sizes from different steels and alloys;
— quick re-adjuster of equipment for new size;
— universal (convertible) technological process for high-quality (without defects) products with small cross section.
It is possible to satisfy these requirements with using method of screw rolling as basic method for micro-metallurgical works. This basic method (screw rolling) is realized within the framework of the united technical system «the technology of the rolling - the design of the rolling mill».
Such solution does allow to obtain high quality of the metal (the plasticity is increased by 15-30%), high productivity, good level of cost.
So, object of the project is elaboration of the technology and equipment for micro-metallurgical plant, and it does allow:
— to solve ecological problems (to decrease dangerous waste into environment;
— to disperse heat-discharge into environment);
— to increase plasticity of metals and alloys after treatment by the screw rolling;
— to increase coefficient of metal utilization;
— to decrease energy expenses for metal production;
— to decrease transport expenses for transportation of scrap and metal product;
— to solve problem with special metal products for atomic power industry;
— to solve problem with supply of small cross section metal product for distant regions.
Team of scientists of State Scientific Center «Bochvar All-Russian Scientific and Research Institute of Inorganic Materials» and Moscow State Institute of Steel and Alloys started to work in this topic because this direction of metallurgy development is perspective idea; and it is possible to appear on the world market with micro-metallurgical technology. Implementation plan of the project includes research and elaboration of equipment for piece aims only. For example, will be possible to elaborate production technology for spring wire from steel EK-173ID, shell tube from HNM-type alloy, protection tube from steel with boron.
First comments (reaction) about this methods of solving this problem are positive (from developed countries too). Collaboration with several western organization is started. The project has a non-military aim and correspond to the tasks and targets of International Science and Technology Center.