Metallurgical Consulting
M HEAVY TECHNOLOGY implements up-to-date technologies at the enterprises built many years ago and develops projects to improve the performance of modern production facilities designed using advanced technologies.
High qualification of the company’s personnel makes it possible to provide metallurgical consulting services.
Over the past decades, the company’s experts participated in the most difficult revamps of metallurgical facilities in the Republic of Kazakhstan, Ukraine, Uzbekistan, Vietnam, the Russian Federation, etc.
Together with its partners, M HEAVY TECHNOLOGY is working on the most difficult for implementation projects to create new technologies in:
– blast-furnace practice,
– sinter production,
– convertor steelmaking,
and other metallurgical industries.
One of the latest developments in the consulting field is the online program Metallic Mind, based on artificial intelligence. Metallic Mind helps solve all kinds of tasks for creating, operating, or modernizing metallurgical enterprises and facilities.
Metallurgy consulting by the company experts and the Metallic Mind program covers:
- Prompt advice in solving any off-nominal and emergency situations;
- Efficiency engineering and optimization of operational processes;
- Automatic calculations and forecasting of operation parameters of the enterprise;
- Enhancement of security systems, provision of comfortable working conditions, and reduction of risks associated with emergencies;
- Reduction of negative environmental impact and improvement of ecological sustainability.
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Scope of Our Metallurgical Consulting Services
Failure Analysis Consultation
Сore activity of M HEAVY TECHNOLOGY in the metallurgical consultancy is improvement of the enterprise efficiency. The company specializes in developing solutions for technological process optimization, enhancing industrial safety and reducing all possible negative impacts resulting from production processes.
Consulting services by metallurgy experts and a wide range of associated services offered by the company depend on the type of production and mainly include:
- Finding “bottlenecks” in technological processes and developing measures to prevent emergencies.
Improvement of reliability of the most loaded components in the process chain through modification of their design:- using polymer and bimetal coatings
- using proprietary designs to increase the durability of critical equipment components, etc.
- Performing an audit of system failures that occur in process chains of:
– sinter production,
– iron and steel melting,
– ferroalloys and titanium production,
– raw material and finished product transportation systems,
– dedusting plants,
– process gas cleaning plants,
– water circulation systems of the enterprises. - Risk estimation for potential emergency situations during operation.
- Environmental audit of production. During metallurgical consulting by M HEAVY TECHNOLOGY experts, the client gets recommendations on minimizing environmental impact.
The company is the author of developments in the field of environment protection with their subsequent implementation in production:
– dedusting plants,
– gas cleaning plants,
– treatment of water effluents, including the creation of zero-discharge closed-loop water systems for industrial enterprises,
– re-use and recovery of secondary metallurgical gases.
Check out industrial dust collection system design and engineering services from M HEAVY TECHNOLOGY.
Metallurgy Tests and Services
Metallurgical consulting company M HEAVY TECHNOLOGY provides metallurgical consulting and analysis for finding the most effective ways to improve existing technologies.
Analysis and selection of optimal equipment and enterprise operation modes as a whole is carried out with the use of innovative technologies:
The CFD mathematical modeling method consists of the following stages:
✔️ Creating an accurate 3-D model of the process unit
✔️ Building a grid model
✔️ Performing calculations with subsequent analysis of the obtained results.
Implementing software-based modeling and simulation complexes makes it possible to carry out experiments with technological processes with a simulation of the physicochemical processes of metallurgical units and identify «bottlenecks.»
This method is applied both for the improvement of existing devices and for designing new facilities, as well as for the analysis of completed engineering.
You can learn more about CFD modeling here: (https://www.mheavytechnology.com/2023/06/10/cfd-modeling/).
2. Calculation studies are supported by the Metallic Mind consulting program. The program offers unique solutions for optimizing technological processes, increasing enterprise productivity, improving product quality, enhancing industrial safety, and reducing the negative impact on the environment.
3. Laboratory research and development of solutions aimed at reducing specific fuel consumption in the processes of metallurgical alloy smelting, minimizing heat losses, reducing waste, and decreasing environmental impact.
Material Selection and Optimization
Metallurgy consultants of M HEAVY TECHNOLOGY specialize in developing solutions for increasing enterprise capacity, optimizing the fuel combustion process, reducing waste, and minimizing environmental impact. The company’s services include the following:
- Selection of raw material preparation methods and production technologies for increasing finished product output in metallurgical processes and reducing generated waste.
- Analysis of the raw material base and examination of existing metallurgical production waste disposal places with the aim of extracting valuable raw materials and their subsequent re-use in the production of sinter, cast iron, steel, ferroalloys, and yellow phosphorus.
- Works on recovery of heat and pressure of flue gases from technological units, water cooling systems with subsequent re-use in hot water supply systems, and indirect heating systems.
- Comprehensive analysis of material and heat balances of the enterprise, which help to identify areas with unreasonably high raw material consumption or significant heat losses. Providing recommendations on the correction.
Metallurgical Processing
Metallurgical engineering consulting by M HEAVY TECHNOLOGY is:
1. Design documentation analysis of the facilities under construction or working enterprises. Identifying weak points in process flows, equipment structures, material balances, and other aspects negatively affecting the entire enterprise operation.
2. An audit of technical solutions to reduce capital costs for construction of technological facilities, including selecting construction materials and construction methods and finding new or alternative technologies for reducing operating costs.
3. During the preparation of facilities for construction or reconstruction, recommendations based on survey results are developed, which include:
✔️ (P&ID, flow sheets);
✔️ Material balances and flow diagrams;
✔️ Layout solutions for equipment, buildings, and structures;
✔️ CAPEX and OPEX calculations.
Check if our services match your expectations
Our Metallurgical Consulting Services Help Our Clients
Our Engineering Process
To contact the metallurgy engineering consultants of M HEAVY TECHNOLOGY and start cooperation, you can give us a call and ask your question or describe the problem you are facing. You can also email us or use the contact form provided above. Our company’s experts will promptly process your request and get in touch with you. You will get a specific work plan that enables you to find solutions for your objectives.
Our metallurgy consulting firm also performs laboratory tests and mathematical modeling of processes – CFD. Thus, performing calculations based on the double of the process unit makes it possible to check all possible operation modes of the object being investigated.
Besides, the company can carry out CAPEX and OPEX calculations for the proposed technical solutions within the scope of consulting services.
The process ends with a detailed consultation and a final document containing all necessary technical and economic solutions.
An additional option of M HEAVY TECHNOLOGY services is the installation of an online consulting program, Metallic Mind, based on artificial intelligence at the Customer’s enterprise, which makes it possible to get all questions answered in real-time throughout the entire life cycle of the enterprise.
M HEAVY TECHNOLOGY metallurgy professionals and engineers
Case Studies of Our Metallurgical Consultants
Let us consider examples of consultations with performing works on modernization and optimization of metallurgical facilities.
- Performing inspection works on the cooling systems of DP-4, DP-5, DP-6, and DP-7 at PJSC NLMK, Lipetsk, with recommendations and solutions to improve their performance.
As part of this work, an analysis of the current situation at the enterprise was carried out, and weak points of the existing cooling systems were identified.
The company has made computer modeling of the processes in blast furnaces, determined thermal loads on the cooling elements, and provided recommendations and solutions which help to increase the blast furnace cooling system stability, reduce heat losses from the cooling systems, and herewith consumption of standard fuel and to assure a stable operation of the furnaces.
Check out blast furnace design services from M HEAVY TECHNOLOGY.
Calculation of blast furnace combustion processes:
Calculation of the thermal load impact on the cooling stave:
- Comprehensive works for determination of reasons for premature tuyere stock failures at BF No. 7, PJSC NLMK, Lipetsk, and at BF No. 4, PJSC Azovstal, Mariupol.
Both works included a review of the tuyere design in use at the time. The company simulated the operating conditions of the tuyeres, analyzed the situation in the tuyere zone, and determined the reasons for the tuyeres’ failures.
The company has provided solutions and detailed engineering drawings for changing the tuyere design based on the work results. The cooling system has also been modernized, and technological processes optimized.
Cast iron and slag drops impact on the tuyere surface:
Combustion zones in the blast furnace:
- Thermotechnical calculations within the scope of the existing project with submitting recommendations on lining modification of the electric ore-thermal furnaces for yellow phosphorus production at the facility: «Kazphosphate» LLP (NDFZ), Taraz.
The purpose of this work was to provide recommendations and specific solutions for the optimization and modernization of yellow phosphorus production, and consequently, a calculation of processes in electric furnaces was needed. Since an electric ore-thermal furnace is a complex electrochemical reactor, complicated processes occur inside the furnace, and it is challenging to use explicit calculation methods. Сomputational CFD (Computational fluid dynamic) and FEM (Finite element method) were used to design such systems. Computer modeling technologies make it possible to conduct complex coupled calculations of various processes, including those occurring in electric furnaces which produce phosphorus.
Temperature distribution inside the furnace:
Temperature isosurfaces inside the furnace body:
- Inspection of the casthouse dedusting systems of blast furnaces No. 4 and No. 6, PJSC «NLMK», Lipetsk, with performing aerodynamic calculations and submitting recommendations.
Investigation of the operating dedusting system was carried out under the project scope. Drawbacks were identified, and dust emission and aerodynamic calculations of the entire dedusting system were performed. Based on it, the company provided new technical solutions for decreasing dust emissions to the required values.
Calculation of dust emissions and the amount of captured dust-air mixture:
- Expertise of two main technical solutions for the investment project “Major Overhaul of Blast Furnace No. 1 in 2023”, EVRAZ ZSMK.
Under this project, our company’s experts conducted a comparative analysis of two companies’ developments regarding the entire blast furnace complex. The analysis encompassed two variants, highlighting their drawbacks and advantages. Recommendations have been provided to enhance the developed solutions to reduce CAPEX and OPEX and increase the furnace complex’s maintenance-free operation period.
- Analysis of operation of the coke gas afterburning system for coke carbonization production at RTF ACTICA Kazakhstan, with solutions for improving the system operation.
This work aimed to discover the reasons for the inefficient operation of the existing coke gas afterburning system. In the course of work the company found an optimal design of the coke gas afterburner, which makes provision for complete coke gas combustion. The company has also made and provided design documentation for the coke gas afterburner.
A volumetric gradient of temperature distribution in the existing afterburner:
A volumetric gradient of temperature distribution in the afterburner of our design:
