LF and VD/VOD plant for Deutsche Edelstahlwerke GmbH Witten, Germany
At the end of the first quarter 2011 INTECO received the order for an important project from long term customer Deutsche Edelstahlwerke GmbH, Witten. INTECO's scope of supply consists of the following:
The construction of a completely new secondary metallurgy center consisting of a ladle furnace, a VD/VOD plant, Level 2 automation system and an alloy addition system all configured for a max. heat size of 130t.
Furthermore INTECO will modernize the already existing ladle furnace, VD/VOD plant, alloy addition sysem and rinsing unit.
This project will be successfully carried out during the next three years.
New secondary metallurgical plant for Saarstahl AG, Germany
End of 2010 the German steel plant Saarstahl AG awarded INTECO with the supply of a new secondary metallurgical plant.
The order includes supply, engineering, assembling and start up of two 200t twin ladle furnaces and one RH plant of the same batch size. Each ladle is equipped with four wire feeding machines, two T&S manipulators, 2 emergency top lances and two nipple stands.
The RH plant is equipped with a steam vacuum pump for vacuum treatment. The ladle is liftet to the vacuum vessel with a hydraulic ladle lifting device.
The start up of both plants is planned for end of 2012/beginning of 2013.
Engineering & Supply of the ladle furnace and vacuum degassing for the Secondary Metallurgical Complex & Ingot Casting for SeAH-Besteel Corporation, Korea
In May 2009 INTECO sucessfully put into operation a new steel plant for SeAH-Besteel Corporation, Korea, consisting of a 160 t ladle furnace, a 160 t vacuum tank degasser and 7 vacuum ingot casting stations. The order was placed by SeAH-
Besteel in January 2008, the equipment was delivered in November 2008 and commissioned within a record time of only 9 weeks. This new plant allows the production of forging ingots between 60 and up to 500 t for large turbines, especially for the power industry.
Several ladles can be casted into one large ingot using INTECO´s vacuum ingot casting technology.
New secondary metallurgical plant at Böhler Edelstahl, Austria
INTECO was awarded this project to deliver the engineering of the steel plant (including equipment, infrastructure, utilities, building, dedusting equipment, alloy addition system, etc.) as well as to supply the ladle furnace, the vacuum degassing unit and the ingot casting equipment.
Based on the mutual trust and confidence between Böhler and INTECO. Böhler has also outsourced their entire project management to INTECO.
The first heat was executed according to the time schedule end of 2009.
Secondary Metallurgical Plant for Breitenfeld AG, Austria
This project was awarded to INTECO in 2007. The engineering of the new plant was done by INTECO. INTECO also handled the entire sourcing of equipment on behalf of Breitenfeld. Ground breaking took place on October, 1st, 2008. With a construction period of less then 6 months an entire secondary metallurgical plant with 2 ladle furnaces, vacuum degassing (VD/VOD), material handling system, ingot casting and the necessary auxiliary equipment (pre-heater, heat treatment furnaces, water treatment, cranes, dedusting equipment, etc.) was erected. The first heat was executed on April 14th, 2009 and even the very first ingot which was produced had such a good quality that it could be sold to the customers of Breitenfeld. The time schedule was exactly kept and the budget was even undercut due to the excellent cooperation of the project teams of Breitenfeld and INTECO.
A special feature of the new plant is the possibility to cast two ladles into one large ingot, thus producing ingots with double heat size of the EAF.
Anglo American project Barro Alto, Brazil
Inteco was contracted by Anglo American for supplying the Ferro-Nickel refinery for the Barro Alto project in the Brazilian state of Goias.
The refinery contained the main process equipment (two primary oxygen blowing stations, two 50 t ladle furnaces, two secondary oxygen blowing stations , deslagging stations) as well as the complete auxiliaries, material handling system and cranes.
Both lines were set in operation in 2011. The first heat for the second refinery line took place in August 2011. As for all Inteco's Ferro-Nickel projects the nominal production capacity was reached within an extra-ordinary short time.
The customer's satisfaction is reflected in the citation of INTECO in Anglo American's corporate news letter stating the outstanding quality of INTECO's equipment and project execution.
FeNi refining plant of MINERAÇÃO ONÇA PUMA Ltd., Brazil
Inteco supplied a complete Ferro-Nickel refining plant for Vale's Onca Puma project in the Brazilian state of Para. Vale S.A., head quartered in Rio de Janero, is one of the leading mining companies world wide. The nominal capacity of 53 000 tons per year of nickel contained in ferro-nickel will contribute a substantial amount to the global nickel market.
The refinery consists of two lines each comprising an oxygen blowing station, a 65 t ladle furnace and related auxiliary equipment. The two lines share one common alloy addition system.
The first line was succesfully set in operation already in February 2011. The first heat at the second line commenced on schedule in October 2011. Assisted by INTECO's experts with long term experience in the refining of Ferro-Nickel the achieved metallurgical results were excellent already after some heats.
INTECO also entered into a long-term cooperation with VALE for technical assistance to further push the performance of the plant.
Engineering as well as project management services for the titanium-melting project of UST-Kamenogorsk, Kazakhstan
For one of the world's largest Titan sponge producers INTECO executed basic and detail engineering works as well as project management services for the design, installation and commissioning of a Titanium Melt Shop to be erected in Kazakhstan.
The project started in 07/2006 and was successfully comissioned in 2010.
Throughout the project INTECO was responsible for the basic engineering of the whole plant, including the definition of equipment and process parameters. The plant is set up with a weighing and blending unit, a compacting press, plasma welding stations and VAR furnaces. INTECO was responsible for the design integration of all process equipment, that has been purchased from third parties as well as for basic design of the shop infrastructure. INTECO was also responsible for preparing tender documents, technical and commercial evaluation of offers and assisting the purchasing procedure.