Modernization of the compressed air production system at the Central Mining and Processing Plant, Metinvest

Metinvest, the international group of mining and metals companies, is constantly investing in the introduction of the latest energy-saving technologies to reduce energy and natural resource consumption. Thus, with the involvement of a partner, YASNO Energy Efficiency, the Group implemented a project to modernize the compressed air system of the central compressor station at Central Mining and Processing Plant (CMP).

Dalgakiran Compressor Ukraine won the tender for the complex of works and equipment supply. Our experts conducted an audit of the existing compressed air production system, developed a solution and installed modern energy-efficient compressor equipment in the premises of the Central Compressor Station with the required performance to ensure all technological processes of the Central Processing Plant’s customers.

Prior to the modernization project, the company’s compressed air supply was provided by three K-250 compressors (one operating, two standby) and a cooling system based on a cooling tower. One of the compressors with a capacity of 15,000 m3/h operated in a constant mode while the compressed air consumption at the Centralized GOK is variable and amounts to 100….225 m3/min (600…13,500 m3/h). The K-250 compressors do not have the ability to regulate capacity and were designed for an operating pressure of 6-8 bar(n), while the operating pressure in the pneumatic system of the Centralized GOK is 3 bar(n). Therefore, excess compressed air was released into the atmosphere. In addition, the cooling tower-based cooling system for the compressors was heavily worn, which also negatively affected the consumption of electricity and cooling water.

The project for the modernization of compressor equipment by Dalgakiran included the following list of works and equipment:

• Conducting an energy and pneumatic audit at the enterprise, developing a technical solution, and selecting equipment.
• Development and approval of project documentation and work execution project with the customer.
• Supply and installation and connection of equipment:
  • IDK TRE60M2 turbocharger with adjustable capacity from 100 to 175 m3/min and an operating pressure of 3.5 bar(n).
• Supply and installation of air ducts and valves, laying of cables within the design solution.
• Automation of the compressed air production system with a visualization system, web interface, a system for metering electricity consumption and compressed air consumption and monitoring other production parameters, integration with the Centralized System of Accounting and Control of GOK.
• Adaptation of the compressor equipment control scheme to the existing protection and alarm scheme.
• Conducting commissioning and acceptance tests, training of customer personnel.

As a result of the turnkey project, the company managed to significantly reduce the energy consumption of the compressed air production system of the Central Compressor Station, improve the reliability and efficiency of the system, and introduce a high level of automation.

Project manager: Alexander Dyadyushkin