Energy Centre for a Metallurgical Enterprise
In 2019, the MKS Group of Companies completed the construction of an energy centre for the largest producer of blanks and bars – NLMK Ural (member of NLMK Group). On November 14, the power complex was put into operation at the production site in Nizhniye Sergi and began to provide the plant with electric and thermal power.
The energy centre of «NLMK Ural» has become the heaviest gas genset power plant in the Nizhneserginsky district of the Sverdlovsk region. The total thermal capacity of the facility is 25,5 MW, and the electric capacity is 4,5 MW. Three 7 MW water heating boilers are used as the main equipment, as well as a 4,5 MW gas genset plant of the MWM 2032В V16 (Germany).
The power plant is operating in a cogeneration mode (simultaneous generation of electric and heat power), when the thermal energy is used not only for production processes, but also for heat supply of the workshops, plant control, administrative and household buildings. The energy centre is fully integrated into the plant's processes and operates in parallel with the power grid. Natural gas is used as fuel for the genset.
The MKS Group of Companies carried out all the turnkey works on the object launch – project design, equipment supply, construction and installation and commissioning works. At the same time, all the works – from the foundation to commissioning – took only 12 months.
A great number of unique technical solutions, many of which have not yet been used in Russia, were implemented at this site by the specialists of the MKS Group of Companies. A great preparation work was carried out, over three thousand cubes of soil were removed, linear networks – gas and electric – were built. In addition, a water treatment system was implemented, which allowed to fully provide the plant with drinking water.
Within just one year a permanent building of the power plant was built at the place of a former open-hearth shop, housing a boiler hall with three water heating boilers, a machine hall with a gas genset plant, an operator's console, utility rooms. And the «heart» of the complex is the MWM gas genset with a capacity of 4,5 MW. It combines the equipment into one complex, and apart from generating electricity, it allows the heat power production.
TCG 2032В V16 is by far one of MWM's most high-power and large-scaled engines. Generator's length is 9.2 m, width – 2,6 m, height – 3,3 m, weight – 56 tons. The engine is characterized by a high degree of reliability and environmental friendliness, as well as by one of the highest efficiencies in the world – 86,5%.
The power plant will allow the NLMK-Ural plant to significantly reduce the costs of production in terms of electric and heat power consumption and will improve economic indicators. According to the calculations the payback period of the energy centre will be 3 years.
The solemn ceremony of the energy centre launch – report
NLMK Ural is a core company within NLMK Long Products Division controlled by NLMK Long. The company produces continuous cast billet, rebar in bars and coils, wire rod. NLMK Ural's operations are located in Revda (EAF plant), Nizhniye Sergi and Beryozovsky (long products).