Norilsk Metallurgists to Independently Construct a Furnace
Self-Making a Custom Resistive Electric Furnace for Nadezhdin Metallurgical Plant
The Nadezhdin Metallurgical Plant in Norilsk is set to reduce costs by creating its own resistive electric furnace, a specialized industrial tool for melting and heat treating metals. This move is expected to save hundreds of millions of rubles.
The electric furnace, also known as an obedientelnaia elektropech', processes slags from blast furnaces and converter slags - byproducts of smelting metallic ores. In this process, valuable metal residues like nickel, cobalt, copper, platinum, and palladium are extracted from the slag mass.
As of now, the Nadezhdin Plant already manages four such furnaces, working 24/7 to process around 2500 tons of raw material daily. The extracted metal species are then processed further for the production of ferroalloys. The effectiveness of the furnace operation is crucial to the plant’s overall productivity.
Since 2022, engineers from the Mechanical Plant of Norilsk Nickel have been designing and refining an innovative in-house technology for casting essential furnace components—key elements of the electric furnace system, especially for cooling systems. In 2023, a trial batch of these components was successfully cast during the significant overhaul of the second technological line of NMZ. These components demonstrated impressive results during testing, paving the way for the production of over 500 of these components, weighing more than 100 tons collectively.
By producing their own electric furnace, engineers can manufacture and assemble it from casting to assembly, eliminating the need for external suppliers and saving over 700 million rubles on procurement costs. The new electric furnace is slated to commence operations at Nadezhdin in February 2026.
Here's a simple breakdown of the process:
- Define Technical Specifications
- Purpose, Temperature Range, Furnace Capacity, Power Supply, Control Requirements
- Design Phase
- Heating Elements, Insulation, Control System, Furnace Body, Power Electronics
- Sourcing Materials & Components
- Heating Elements suitable for Norilsk’s climate, Refractory materials, Electrical control hardware
- Fabrication & Assembly
- Furnace Chamber, Heating Elements, Control Panel, Sensors, Ensuring Sealing and Insulation
- Testing & Commissioning
- Dry Tests, Temperature Calibration, Power Optimization
- Integration into Production
- Operator Training, Monitoring Performance, maintenaance
Now that's a game-changer for the plant, providing various benefits such as:
- Energy Efficiency: tailored design reduces overconsumption and waste, leading to significant energy savings.
- Cost Savings: lower initial investment and maintenance costs by employing a custom design suitable to local conditions.
- Operational Advantages: consistent product quality, quick customization for different production runs, and reduced downtime.
- The news of the Nadezhdin Metallurgical Plant creating a custom resistive electric furnace, also known as an 'obedientelnaia elektropech', signifies a significant shift towards self-manufacturing in the industry.
- The advancement in science and technology, as applied in manufacturing, would likely influence other plants to adopt custom technologies for various medical-conditions treatments and finance management.
- With the success of in-house technology for casting essential furnace components, the impact extends beyond the manufacturing industry, potentially revolutionizing science and technology solutions for different sectors, such as medical-condition treatments and finance management.
