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STEEL MELTING WORKSHOP NO. 1 |
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Open-hearth plant was commissioned in 1932 year and already on the 9th of 1933 open-hearth plant staff among the first at "Krammashstroy" proceeded to products output. In February of 1946 year the first runner for Dneproges was casted. 140t of liquid metal was needed for die casting. Steel was melted in two open-hearth furnaces. Workshop total area is 26432 m2. In 2007 year Open-hearth plant was renamed into Steel melting workshop No. 1 in connection with changing of steelmaking practice. On July 31st electric arc furnace complex (EAF-50) with 50 t capacity was commissioned and brought to operating mode. EAF-50 implements new steelmaking practice which enables to manufacture any steel grade and provides total chemical composition repeatability at each melt. This practice also enables to expand the output significantly, to melt the liquid steel of particular high quality with low content of detrimental impurities, gases, non-metallic inclusions and to manufacture 170 t ingots. After-furnace ladle steel treatment unit was made in consortium with Moldavian metallurgical works and enables to carry out the following production steps: correction and homogenizing during metal treatment at LFU; reduction of melts duration in open-hearth and electric arc furnaces; using of ladle furnace unit as metal accumulator in mixing mode, enables to manufacture ingots with the weight up to 170 t. |
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Steelmaking units of metallurgical production unit: - two open hearth furnaces with the 50 and 55 t capacity; - two electric arc furnaces with the capacity 10t; - electric arc furnace complex EAF-50 with the capacity 50 t Open-hearth and electric arc furnaces are used for liquid steel melting with its subsequent treatment at ladle furnace unit as well as for independent steel melting for forgings and mold castings. Vacuum steam jet pump. Vacuum steam jet pump was manufactured and commissioned in 1999. Operating pressure 0,4 – 0,5 mm Hg in vacuum system is reached by means of vacuum steam jet pump. Hydrogen content in steel after its vacuum pouring is not more than 2 ppm. Vacuum steel treatment can be carried out in stream (ingots casting in vacuum) as well as in ladle (ladle with metal vacuum treatment in vacuum chamber No. 4). In the workshop equipment was made and vacuum-oxygen decarburization technology got accepted in production for low-carbon stainless steels melting that enables to expand the blanks assortment for power engineering industry. |
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PRESS-FORGING WORKSHOP NO.2 |
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Press-forging workshop No.2 (PFW-2) was put into operation on December 20, 1934. At the present time in the workshop hydraulic presses with the capacity 10000 tf and modernized forging complex 3000 tf are used which enable to forge propeller shaft forgings with the length up to 24000 mm, shrouds up to 4700 mm, back-up and work rolls, eccentric shafts, plates, spindles, rotors, disks, arms and others. Modernized forging complex 3000 ft specializes in manufacturing of forgings for mill work rolls and parts of machines produced by our plant. Over recent years in PFW-2 7 horizontal and 11 vertical heat-treating furnaces with ceramic-fiber lining were implemented which operate in automatic mode with temperature gradient = ±2 oC along the whole length of operating space that enables to execute qualitative modes of heat-treatment for parts with high properties. 5 low-temperature furnaces were implemented for cold rolling rolls quenching after induction quenching. New heating furnace has been built and is implemented at the VIth bay. 2 heating furnaces with ceramic-fiber lining have been built and they operate in automatic mode. It enables to carry out qualitative modes of blanks heating. |
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MACHINING WORKSHOP NO. 3 |
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Machining workshop No.3 was put into operation in 1934 and is one of the plant main shops. Workshop construction was envisaged together with PFW-2 on the ground of closeness to blank production. Workshop layout was planned for manufacturing of parts having bodies of rotation shape. Workshop production activity consists in products output of the following assortment: rolls for cold and hot rolling, herringbone rolls, spare parts for metallurgical, press and forging, crushing and grinding, excavating equipment and so on. Technology of composite rolls manufacturing was mastered by the workshop over recent years. In connection with severization of requirements for technical characteristics of rolls – their quality and accuracy, reconstruction of the following equipment had been carried out in the workshop: | |||
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Using of leading cutting equipment and implementation of organizational measures complex raised labour productiveness, allowed to improve the quality of output products while lowering the labor intensity of its manufacturing. At the present time machining center TOS KURIM and circular grinding machine HERCULES have been put into operation in the workshop. |
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MACHINING WORKSHOP No. 1 |
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Machining workshop No.1 was commissioned on May, 14, 1933. It was the biggest workshop at the plant. All the most sophisticated and new equipment was manufactured in machining workshop No.1. In this workshop bed for slabbing mill shears was machined – it was the first blank with weight over 100 t in the history of Europe. Staff of machining workshop No.1 had finished the manufacturing of the first soviet tunneling machine for subway tunneling up to May, 1, 1936. Machining workshop manufactured and is manufacturing now rolling mill equipment for integrated iron and steel works of Ukraine, for near and far abroad, spare parts for metallurgical equipment. Manufacturing of CCM segments was mastered. |
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Technical reequipment is always going on in the workshop. One of a type equipment was installed: At the 1st bay of machining area:
At the 2nd bay of machining area:
At the 3rd bay of machining area:
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At the 4th bay of machining area:
Infra red heaters are installed on the I, II and III bays.
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REDUCTION GEAR SHOP |
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On December, 20, 1932 machining workshop "Á" was put into operation and it was renamed into Reduction gear shop and Machining workshop No. 2 in 1944. Reduction gear shop is geared to manufacturing of gear units high-product mix that are used in units, devices and machines of rolling mill, metallurgical, press-forging and ore-mining equipment. The following high-performance equipment is installed in the workshop: |
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MACHINE-ASSEMBLY WORKSHOP NO. 14 |
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Machine-assembly workshop No.14 was commissioned in 1961. Workshop facilities are intended for ground handling equipment manufacturing for aircraft defense and ballistic missile defense systems of Defense Ministry, World Resources Institute and other special-purpose equipment. |
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Products of military-industrial establishment such as space-ports equipment, launching towers, erectors, equipment for launching silos, one of a type "Buran-Energy" complex and so on composed about 30 per cent of total output. There are four areas in the workshop: one – area of machining and three ones – areas of assembly where assembling of handling and mining equipment is carried out. |
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SPECIAL TOOLING WORKSHOP |
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Special tooling workshop of NKMZ was put into operation in September, 1974 and was intended for manufacturing and recovery of metallurgical, welding and machining tooling of modular instruments, cutting tool for machines with numerical program control.
Equipment of leading Europe companies was purchased, installed and is efficiently used since 2001 in accordance with developed plant strategy up to 2010 year:
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Tool with mechanical fastening previously not manufactured in Ukraine was designed in electronic form and got accepted in production of the plant by design engineers and tooling engineers together with the workshop workers:
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Wide range of metal-working equipment, possibility of control, active designing and engineering development by specialists of Tooling Department and workshop enables to extend the producibility in the workshop sufficiently. Press-moulds, hydraulic blocks, burners, diaphragm dies are also manufactured in the workshop. |
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MACHINING WORKSHOP NO. 8 |
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Machining workshop No.8 consists of five bays where two areas of machining and three assembling areas are located. Machine tool population of the workshop comprises big boring machines with spindle over 200 mm, main part of which is presented by machines with numerical program control and modernized equipment. Range of production:
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At the 7th bay the following equipment is located:
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MACHINING WORKSHOP NO. 7 |
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Machining workshop No.7 was commissioned on June, 6, 1984 on the basis of the second area of machining workshop No. 5 as a dragline workshop for units and mechanisms manufacturing and for unique machines and draglines assembling. Since April, 16, 1959 machining workshop No.7 started manufacturing of rolling mill (slabbing mills, wide-strip mills, rolling mills, back-up rolls), press-forging (presses with the capacity 6300t and over), ore-mining ( mine winders, ore-grinding and coal-grinding mills of different standard sizes and spare parts for them), cranes and belt conveyors. |
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Technological reequipment of machine tool population is carried out extensively. 12 units of high-accuracy equipment (machines with numerical program control and machining centers) were commissioned:
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Plain grinding vertical turning NC machine and cutting band were commissioned. Besides, modernization of old machines such as boring machine, plain-milling boring machine of Ulyanovsk plant was effected. As a result of modernization besides recovering of technical capacities of the equipment, machines were equipped with controlling means of Siemens that allowed to reduce products manufacturing cycle. |
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MACHINING WORKSHOP NO.5 |
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Machining workshop No. 5 was put into operation in September 1936. Workshop is specialized in machining of back-up and work rolls, rotor shafts, propeller and intermediate shafts, hydraulic cylinders, stems, plungers and others. Machining workshop No. 5 manufactures unique banded back-up rolls with the following weight:
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Unique equipment operates in the workshop, namely:
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