Tikhvin Smetling Ferrochrome plant

• Sunday, June 6, 2010
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Tikhvin Smelting Plant, Russia

 

 

The Tikhvin Smelting Plant is designed to receive and smelt chrome ore into high carbon ferrochrome for use predominantly in the stainless steel industry. The other raw materials used in the ferrochrome smelting process are metallurgical coke as a reductant and a quartzite flux.

 

The plant is situated in the small town of Tikhvin, 200km south east of St Petersburg, Russia. The smelter site is situated in an industrial sanitation zone on the outskirts of the town, adjacent to an existing industrial complex.

 

The climate of the smelter site is strongly continental with very cold temperatures (-20⁰) for extended periods in winter and hot summers (+30⁰). Permafrost conditions do not prevail at the smelter site.

 

Construction of the plant has been completed and first producton commenced in April 2007.

 

Off Take

 

In July 2007 Oriel accepted the initial sales of high carbon ferrochrome product from Tikhvin, representing Oriel抯 first revenue from current working projects.

 

The Tikhvin plant consists of:

• Unloading areas for material stocking
• Briquetting plant
• Batch materials preparation and feeding
• Batch materials feeding system
• Smelter and
• Slag processing

Key statistics of the plant are:

• Phase 1 (2007 ?2010) production capacity of 148ktpa FeCr using feed of 330ktpa chrome ore and concentrate
• Phase 2 (2011 onwards) full production capacity of 180ktpa FeCr using feed of 400ktpa
• Four semi-closed submerged DC arc furnaces with full production capacity of 22.5 MVA each (at 180,000tpa)
• Four gas cleaning plants
• Stage 1 chromite ore initially imported  - then from Oriel's own Voskhod chrome project, Kazakhstan (from mid 2008)
• Average chromite ore grades of 48% lumpy, 57% fines and
• Average composition of chromite feed of 70% fines and 30% lumpy.

Production

At full production in 2011 (Phase 2) the smelter is expected to produce approximately 180,000tpa of ferrochrome. The ferrochrome product will contain approximately 70%Cr metal and is manufactured by smelting a chromite product (40-50% Cr₂o₃) along with fuel (coke) and a flux (quartzite).

 

The ferrochrome is expected to be sold to regional markets through an off-take agreement with a local trading company. At full production, by-product slag will be produced at the rate of 190,000tpa and will be sold locally as a construction aggregate. The smelter is electrically powered and has been under construction since 1996.

 

The design of the furnace is robust and, apart from the electrode assemblies, no unusual or extraordinary breakdowns should occur.

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