Strategic Overhaul Targets Core SteelmakingInfrastructure
Kametstal, a key steelmaking facility within the MetinvestGroup portfolio, has embarked on an extensive renovation of one of its mostcritical production assets, the Basic Oxygen Furnace vessel No. 1. This majormaintenance initiative forms a central component of the company's planned 2025overhaul program, reflecting a strategic commitment to maintaining andenhancing core steelmaking infrastructure. The comprehensive projectencompasses substantial upgrades to the converter's main equipment and powersystems, addressing multiple aspects of the vessel's functionalitysimultaneously. By undertaking this complex renovation, Kametstal aims toextend the operational lifespan of the converter while improving itsreliability, efficiency, and environmental performance. The timing of thisinvestment signals confidence in the continued importance of steel productiondespite ongoing market challenges and underscores Metinvest Group's long-termcommitment to maintaining competitive manufacturing capabilities through systematicequipment modernization.
Gas Exhaust System Modernization Takes CenterStage
At the heart of the renovation project lies a comprehensivemodernization of the converter's gas exhaust system, a critical component thatmanages the substantial volumes of high-temperature gases generated during thesteelmaking process. The scope of work includes replacement of multiple keycomponents: tuyere caissons, auxiliary caissons, and the lower section of themain caisson, colloquially known as the "skirt", along withprotective screens that shield surrounding equipment from extreme heat andparticulate matter. Simultaneously, technicians are replacing both the statorand rotor of the flue gas blower electric motor, essential for maintainingproper gas flow through the exhaust system. These upgrades are particularlysignificant as they directly impact both operational efficiency andenvironmental performance. A properly functioning gas exhaust system ensuresoptimal capture of process gases, reducing fugitive emissions while enablingmore consistent temperature control during the steelmaking process. Thiscomprehensive approach to exhaust system renovation demonstrates Kametstal'sattention to both production efficiency and environmental responsibility.
Precision Engineering Tackles Massive SupportBearing
One of the most technically demanding aspects of theoverhaul involves the manipulation of the converter's support bearing, acritical component that enables the massive vessel to rotate during thesteelmaking process. This operation requires extraordinary precision despitethe enormous scale involved, as technicians must lift the entire convertervessel weighing more than 1,000 metric tons to access and turn the outer cageof the bearing. This complex procedure, which can only be performed during acomplete shutdown, will extend the service life of this crucial component byredistributing wear patterns across the bearing surface. The engineering teamis also taking advantage of this rare access opportunity to thoroughly inspectand update the lubrication system that keeps this massive bearing functioningsmoothly under extreme loads. The successful execution of this high-precisionoperation on such a massive scale demonstrates the sophisticated engineeringcapabilities maintained at Kametstal, combining heavy industrial techniqueswith meticulous attention to detail.
Refractory Lining Replacement Enhances ThermalEfficiency
Another major component of the overhaul involves thecomplete replacement of the converter vessel's refractory lining, thespecialized heat-resistant materials that protect the steel shell from theextreme temperatures of molten metal, which can exceed 1,600°C duringoperation. The dismantling phase of this process has already been completed,removing worn materials that had reached the end of their service life. Theinstallation of new refractory materials will follow a carefully designedpattern that optimizes both thermal protection and operational longevity.Modern refractory systems incorporate multiple layers of specialized materials,each selected for specific thermal and chemical resistance properties based ontheir position within the vessel. Beyond merely protecting the vesselstructure, an optimized refractory lining improves thermal efficiency byreducing heat loss, potentially lowering energy consumption during thesteelmaking process. This comprehensive replacement represents a significant materialinvestment but provides essential protection for the converter vessel whilepotentially improving operational economics through enhanced thermalefficiency.
Comprehensive Scope Extends Beyond PrimaryEquipment
According to Andriy Zuev, Deputy Head of the BOF Shop forEngineering, the renovation extends well beyond the converter vessel itself toencompass the entire supporting infrastructure that enables continuousoperation. This holistic approach includes attention to oxygen supply machinesthat deliver precisely controlled volumes of oxygen to the converter, pumpingunits that manage various fluid systems, vertical ducts that channel materialsand gases, and the specialized steel carriers and slag carriers that transportmaterials to and from the converter. By addressing this complete ecosystem ofinterconnected systems, Kametstal ensures that all potential bottlenecks andwear points are addressed simultaneously, maximizing the benefits of theshutdown period. The work spans mechanical, electrical, and power systems,reflecting the multidisciplinary nature of modern steelmaking operations andthe need for integrated approaches to maintenance. This comprehensive scopedemonstrates sophisticated asset management practices that recognize theinterconnected nature of industrial systems rather than treating equipment inisolation.
Vessel Integrity Restoration Enables FurtherUpgrades
A critical milestone already achieved in the renovationprocess has been the repair of the converter body itself to restore itsgas-tight integrity. This fundamental restoration was a prerequisite forproceeding to more advanced aspects of the overhaul, particularly the complexbearing rotation operation. The converter vessel must maintain precisedimensional specifications despite being subjected to extreme thermal cyclingand mechanical stresses during normal operation. Over time, these forces canlead to subtle deformations that compromise sealing surfaces and alignment. Thesuccessful restoration of vessel integrity demonstrates the technical team'sability to address these fundamental structural issues, providing a soundfoundation for the subsequent upgrades. This methodical approach to therenovation process, addressing fundamental structural integrity beforeproceeding to mechanical systems and finally to operational components,reflects well-established engineering principles for major equipment overhaulsin heavy industry.
Investment Signals Confidence in Steel SectorFuture
The timing and scope of this significant investment in coresteelmaking infrastructure provide insights into Metinvest Group's strategicoutlook for the steel industry. By committing substantial resources to thecomprehensive renovation of a major converter vessel, the company signalsconfidence in the continued importance of steel production despite ongoingmarket volatility and economic uncertainties. The focus on modernizingenvironmental control systems alongside production capabilities also reflectsawareness of evolving regulatory requirements and sustainability expectations.Rather than pursuing minimal maintenance to extend operations marginally, thiscomprehensive approach suggests a longer-term perspective that values robust,efficient, and environmentally sound production capabilities. The investment inKametstal's BOF vessel renovation thus represents not merely a maintenanceexpense but a strategic positioning of assets to remain competitive in anevolving market landscape where operational efficiency and environmentalperformance increasingly influence competitiveness.
Key Takeaways:
• Kametstal's comprehensive overhaul of BOF vessel No. 1includes modernizing the gas exhaust system with replacement of tuyere andauxiliary caissons, the lower part of the main caisson, and protective screens,directly impacting both operational efficiency and environmental performance.
• Engineers are executing a technically demanding operationto turn the support bearing, requiring the lifting of more than 1,000 metrictons of the converter vessel, which will extend the bearing's service life andimprove operational reliability.
• The renovation extends beyond the primary converter toencompass the entire supporting infrastructure, including oxygen supplymachines, pumping units, vertical ducts, and material carriers, reflecting aholistic approach to facility maintenance across mechanical, electrical, andpower systems.
