A new turbo-compressor is under assembly at the oxygen station of Nadezhda Metallurgical Plant

Oxygen station located at the Nadezhda Metallurgical Plant site in the Polar Division replaces one of 15 turbo-compressors for oxygen and nitrogen production.

To maintain compressor machinery of the oxygen station in good operating condition and to procure major assemblies and parts to replace expiring ones, the company annually spends about 50-70 million rubles. Therefore, in 2014, it was adopted general concept of replacement of compressor machinery of the Nadezhda Metallurgical Plant oxygen station. Implementation of this concept will significantly reduce compressor maintenance costs, improve efficiency of one of the most energy-consuming process stages of the Polar Division.

Domestically produced turbo-compressor being replaced has been operated by the station for 26 years and then decommissioned due to wear and tear of its basic assemblies.
A new imported compressor is designed for air compression and feeding it to air separation units of the oxygen station for further production of oxygen and nitrogen which come to technological process stages of the Nadezhda Metallurgical Plant and Copper Plant.

New equipment has 113,000 m3/h capacity with power input of10.2 kW. Dimensions: length — 13 m, width — 7.5 m, height — 5.8 m. The unit weight is 148 tons.

The key difference of the new air compressor is its high energy efficiency. In particular, with the same power input, performance of the new compressor is higher by 25%.

Besides, the compressor regulation allows it to reduce discharge by 30% with planned reductions in oxygen consumption that allows it to save electricity considerably. According to specialists, when replacing machinery of air compressors, the company could save up to 70,000 MW per year.

The compressor automation system includes vibration monitoring system through which it is possible to analyze and identify at the early stages deviations in operation of the main compressor assemblies, which would provide an opportunity to significantly reduce costs and time for unscheduled repairs.

To date, 75% of compressor unit major parts mounting have been completed. At the next stage it is planned to perform automation and electrical works with subsequent start-up and commissioning. Commercial operation of the new compressor is planned for Q3 2016.