MMC Norilsk Nickel undertakes production modernization project worth Rub2.2 bln

OJSC MMC Norilsk Nickel implements a project of metallurgical production modernization at the OJSC Kola MMC site in Zapolyarny (Murmansk Area).

The project will allow replacement of the existing pelletizing-roasting circuit generating a considerable amount of non-treatable gaseous SO2 with concentrate briquetting process where no roasting is required.

The project is a part of the metallurgical production modernization program put into action by Kola in order to reduce sulphur emissions and generation of heavy metal dust/residues.

The existing process involves filtration and roasting of copper-nickel concentrate into pellets going for smelting. In the course of roasting a part of contained sulphur is burnt out and discharged into atmosphere as the original smelter flow sheet did not include sulphur capture at the stages of pelletizing and roasting.

Introduction of concentrate briquetting will upgrade the facility into a modern, efficient and highly automated plant, and will allow dismantling of the overage pelletizing equipment.
The new environmentally friendly process at the Zapolyarny site is expected to cut SO2 emissions fortyfold from 40,000 to 1,000 tpa and to limit dust emission to 106 tpa max.

The new production site will help the Company increase base metal extraction and product output across its operations, diminish crude oil consumption by 1.8 times and reduce energy, operational and maintenance costs.

Elimination of extremely hazardous and harmful workplaces will substantially improve labor conditions, and production automation will result in a two-fold increase in labor productivity, while the released personnel will be transferred to other operations of the Company.

Total project cost will exceed RUB2.2 bln.

According to Vladimir Strzhalkovsky, General Director of MMC Norilsk Nickel, «The Company has adopted a most advanced approach to the industrial modernization by factoring all the aspects of sustainable development, i.e. economic, environmental and social, in the development of this project. Ultimately, Norilsk Nickel will operate an up-to-date, efficient and non-polluting production facility that will improve the Company’s performance indicators».

Process flow sheet was developed by Gipronickel Institute, the Company’s research and engineering unit acting as a General Project Manager. At the initial stage of the project, the Company carried out a large-scale trials that involved briquetting of 1,800 tons of concentrates of its own make.

The following key developments will take place in the framework of this project:

— Briquetting equipment installation at the site of renovated Kola MMC’s concentrator.
— Installation of Larox press filters (Finland) for slurry filtering and wet concentrate production.
— Primary and auxiliary briquetting equipment will be supplied by Maschinenfabrik Köppern GmbH & Co.KG (Germany). Briquette-presses of this company successfully operate at the Mednogorsk Copper-Sulphur Plant, that were used by the Company in the trial tests.
— Two briquetting lines will be installed at the concentrator site, with combined annual capacity of 450 ktpa (in terms of concentrate processing).
— Construction of a new automated storage facility for the final products (4,000 tons). The facility will be equipped with an automatic briquette counting systems and a car positioning system (cars will be used to transport briquettes to the smelter).
— As a liquid binding agent in the briquette production, lignosulphonate will be used (wastes of paper mills).
— To ensure sufficient volume of compressed air, a new compressor station will be built.

Ongoing project activities include the following: preparation of working documentation is almost completed, primary production equipment worth one billion roubles is purchased, the concentrator is under reconstruction, ground works at the briquette storage facility and compressed air station are close to completion.

Key project phases:

— December 2009 - completion of the main building for the briquetting section;
— August 2010 – commissioning and trial operation of the first line (start-up and adjustment);
— November 2010 - shut-down of the first roasting line;
— February 2011 – commissioning of the second briquetting line;
— July 2011 – briquetting section ramp-up to the designed capacity; adjustment and fine tuning of automation equipment; decommissioning of pelletizing and roasting section;
— February 2012 – project completion.