170
A. Liu et al.
Plant A
This plant transformation involved conversion of a sinter plant blast furnace
configuration to enhance environmental performance. Trade-off studies involved:
• Replacing only the sinter plant with new technology
• Replacing both the sinter plant and blast furnace.
The process commenced at preliminary process engineering and involved an
extensive site visit to collect data, drawings, discuss possible locations for the new
plant and to discuss interactions with the existing facility, including how best to
incorporate the new plant. The process was interactive with the site technical and
development team to ensure that the Worley project team knew all the site-specific
limitations that would impact the final process design.
After completing the trade-offs and looking at the condition of the existing equipment on site, the ultimate decision was made to replace both the sinter plant and blast
furnace with a single batch TSL facility. This simplified the modifications that were
required on the plant. The new TSL feed conditioning plant, TSL facility, and off
gas handling could be fitted into the existing facility. The batch operation involved
running an oxidation process for a certain period and then changing to reduction.
This had downstream impacts on the SO 2 capture plant as for some time, during the
reduction process, there were little of no SO 2 laden gases delivered to the off gas
handling plant.
The project was a brownfield modification, and Worley worked from process
design to advanced basic engineering on the conventional flowsheet and then an
advanced basic engineering on flowsheet modifications following a value engineering
exercise and part detailed design. Worley also provided management assistance and
systems for the Owners Engineering Team, construction assistance completions and
commissioning, coordination and support were provided.
Worley, between 2008 and 2014, completed:
• Process (conceptual) design including ±50% CAPEX
• Basic engineering on the conventional flowsheet including ±15% CAPEX
• Cost reduction and value engineering exercise to reduce CAPEX
• Tendering and award of key technology packages
• Advanced basic engineering on the final flowsheet
• Detailed design of hot metals handling and slag granulation systems
• Detailed design of OSBL infrastructure and utilities.
Key management roles and assistance including systems for the Owners Engineering Team, construction assistance completions and commissioning, coordination, and
support were provided.
The plant has reached more than name plate capacity, and an additional benefit
has been an overall reduction in energy consumption at the plant of over 30%.
A. Liu et al.
Plant A
This plant transformation involved conversion of a sinter plant blast furnace
configuration to enhance environmental performance. Trade-off studies involved:
• Replacing only the sinter plant with new technology
• Replacing both the sinter plant and blast furnace.
The process commenced at preliminary process engineering and involved an
extensive site visit to collect data, drawings, discuss possible locations for the new
plant and to discuss interactions with the existing facility, including how best to
incorporate the new plant. The process was interactive with the site technical and
development team to ensure that the Worley project team knew all the site-specific
limitations that would impact the final process design.
After completing the trade-offs and looking at the condition of the existing equipment on site, the ultimate decision was made to replace both the sinter plant and blast
furnace with a single batch TSL facility. This simplified the modifications that were
required on the plant. The new TSL feed conditioning plant, TSL facility, and off
gas handling could be fitted into the existing facility. The batch operation involved
running an oxidation process for a certain period and then changing to reduction.
This had downstream impacts on the SO 2 capture plant as for some time, during the
reduction process, there were little of no SO 2 laden gases delivered to the off gas
handling plant.
The project was a brownfield modification, and Worley worked from process
design to advanced basic engineering on the conventional flowsheet and then an
advanced basic engineering on flowsheet modifications following a value engineering
exercise and part detailed design. Worley also provided management assistance and
systems for the Owners Engineering Team, construction assistance completions and
commissioning, coordination and support were provided.
Worley, between 2008 and 2014, completed:
• Process (conceptual) design including ±50% CAPEX
• Basic engineering on the conventional flowsheet including ±15% CAPEX
• Cost reduction and value engineering exercise to reduce CAPEX
• Tendering and award of key technology packages
• Advanced basic engineering on the final flowsheet
• Detailed design of hot metals handling and slag granulation systems
• Detailed design of OSBL infrastructure and utilities.
Key management roles and assistance including systems for the Owners Engineering Team, construction assistance completions and commissioning, coordination, and
support were provided.
The plant has reached more than name plate capacity, and an additional benefit
has been an overall reduction in energy consumption at the plant of over 30%.