Magnitogorsk Iron Research Articles

Assessment of black carbon emissions in the area adjacent to the Magnitogorsk Iron and Steel Works

Assessment of black carbon emissions in the area adjacent to the Magnitogorsk Iron and Steel Works

Пути повышения конкурентоспособности российских металлургических компаний

The authors explore ways to improve the competitiveness of Russian metallurgical business on the example of two leading companies in the industry - PJSC Severstal and PJSC Magnitogorsk Iron and Steel Works. The article analyses the strategies, financial results and methods used by these companies to strengthen their market positions, including investments in production modernisation, the introduction of innovative technologies, the development of strategic partnerships and a focus on environmental sustainability. The key highlights and achievements of each company are discussed, as well as their contribution to the development of the Russian steel industry. The article concludes by highlighting the key factors contributing to successful competition in the global market and offers recommendations to further improve the competitiveness of the Russian metallurgical complex.

Пути повышения конкурентоспособности металлургического комплекса России

The authors explore ways to improve the competitiveness of Russia's metallurgical complex on the example of two leading companies in the industry - PJSC Severstal and PJSC Magnitogorsk Iron and Steel Works. The article analyses the strategies, financial results and methods used by these companies to strengthen their market positions, including investments in production modernisation, the introduction of innovative technologies, the development of strategic partnerships and a focus on environmental sustainability. The key highlights and achievements of each company are discussed, as well as their contribution to the development of the Russian steel industry. The article concludes by highlighting the key factors contributing to successful competition in the global market and offers recommendations to further improve the competitiveness of the Russian metallurgical complex.

Modernization of Coke Production at Magnitogorsk Iron and Steel Works (MMK)

Modernization of Coke Production at Magnitogorsk Iron and Steel Works (MMK)

Influence of coke size on the performance of a blast furnace equipped with a cone charging device under the conditions of Magnitogorsk Iron and Steel Works

Influence of coke size on the performance of a blast furnace equipped with a cone charging device under the conditions of Magnitogorsk Iron and Steel Works

“We Created Ourselves and the city”: Women's Contribution to the Development of Magnitogorsk in the 1950-1960s

The everyday life of Soviet women during the years of the Khrushchev thaw is one of the insufficiently studied issues of Soviet women's history. This article is devoted to its study using the methods of gender anthropology and multi-focal ethnography of urban life. Its analysis is based on: heterogeneous empirical material - published memoirs of contemporaries, their oral stories (recorded by the authors of the article), materials from periodicals, neglected works of fiction, and visual sources. Magnitogorsk was chosen as the main research locus due to it being a large non-administrative industrial center that had appeared even before the war, and in which demographic gender imbalance persisted even after 1945. After analyzing the features of the women’s contribution to the formation of a new image of the city, the authors completed the picture of the lifestyles of urban women, showing several social types that changed the face of the industrial giant: architects, housewives, social activists, workers of the Magnitogorsk Iron and Steel Works. The collected material showed the success of the Soviet Union’s new social policy, which was an innovative transition of the Soviet state from the harsh methods of management of the 1930s - early 1950s to Soviet democracy, including recognition of the importance of private life, including of Soviet women. However, everyday life of Soviet women from a half a century ago also revealed a number of issues such as: gender inequality and has the exposed the difficulties of organizing everyday women's domestic (family) and industrial life. By proving the importance of gender anthropology as an approach that expands the ability to analyze social idealism and hopes of the political thaw, this approach helps frame the period by showing how gender interacted with the shifting value-normative structures of Soviet thinking and the social image of the female builders of socialism.

Analysis of dynamics of black carbon emissions in the territory adjacent to the Magnitogorsk Iron and Steel Works

Analysis of dynamics of black carbon emissions in the territory adjacent to the Magnitogorsk Iron and Steel Works

Information-modeling system for prediction of the composition and properties of final slag in a blast furnace in real time

The article considers general characteristics of the algorithm for prediction of the composition of the final slag in a blast furnace in real time. This algorithm is based on fundamental knowledge on the processes occurring in the furnace and general laws of transient processes. It allows predicting at the current moment of time and for every hour ten hours ahead. A linearized model of the blast furnace process and a natural-mathematical approach are used. The model takes into account the dynamic characteristics of blast furnaces in various impact channels, which change and depend on the type of impact, operating parameters of the furnaces and properties of the melted raw material. This makes it possible to adjust the model to operating conditions of the object, to take into account changes in the composition and properties of iron ore and coke, blast and regime parameters of blast furnace smelting when modeling. The software of the information-modeling system for prediction of the composition and properties of the final slag in a blast furnace in real time was developed in the C# programming language based on the ASP.NET MVC framework using the .NET 5 cross-platform. The web application includes the following main functions: visualization of change APCS parameters and design parameters over time; slag mode diagnostics; modeling of transient processes of composition and properties of slag; prediction of slag composition and properties in real time and prediction history. The software architecture is described and its operation is illustrated. An assessment of the accuracy and reliability of the simulation results based on statistical indicators was carried out. The root-mean-square deviation of the predicted basicity of the CaO/SiO2 slag from that measured at taps is 0.023, the prediction reliability is 92 %, which indicates a satisfactory agreement between the predicted and actual values of the content of individual components in the slag. The information modeling system developed on the basis of the presented algorithm is integrated into the information system of the blast furnace shop of PJSC Magnitogorsk Iron and Steel Works.

Pyrometallurgical Technology for Extracting Iron and Zinc from Electric Arc Furnace Dust

This study is aimed at developing a technology for processing electric arc furnace dust (EAFD) into granulated cast iron and a zinc-containing product. The study object was the dust from the EAF of PJSC Magnitogorsk Iron and Steel Works (Magnitogorsk, Chelyabinsk region). It has been established that the dust contains valuable components in the form of ZnFe2O4 and ZnO. The processing of EAFD involves the reduction of Fe and Zn in a charge from their oxygen-containing forms with C and CO. The content of the charge components was calculated in % as follows: EAFD—17.44; scale—51.33; hard coal—20.61; quartz sand—4.71; lime—5.91. The experiments in the high-temperature LHT 08/17 furnace (Germany) allowed for defining the optimal temperature regime for reduction melting. As a result of laboratory tests, granulated pig iron samples were obtained, containing in wt%: Fe—95.27; C—4.4; S—0.07, and others. Captured zinc-containing product after calcination (to remove halogens) contained 90.21 wt% ZnO. The resulting granulated pig iron is recommended as one of the charge components in electrometallurgical steel production. The zinc-containing product is recommended as a raw material for Zn production and others.

Plate Mill Stand Electric Drive Control in Asymmetrical Rolling Mode of the Strip Plate Head

An urgent problem that arises in rolling flat steel and plates is to form the preset strip plate head skid-shaped curvature. This is implemented by adjusting the ratio (mismatch) between the top and bottom rolls in the rolling mill horizontal stands. The factors influencing the strip plate head curvature at the stand exit are listed. With reference to the 5000 plate mill of PJSC Magnitogorsk Iron and Steel Works, the article analyzes the top and bottom roll speeds in the “skid” formation mode. The main drawback of the existing electric drive control system is that it controls the speeds as a function of the difference between their current (actual) values. This results in that the drive of one roll reaches a limitation with loss of motor controllability and uncontrolled strip plate curvature. To eliminate this drawback, a new control method was developed, according to which the electric drive speeds are adjusted as a function of the difference between the speed setpoint signals at the inputs of speed controllers. The control system structure implementing this method is considered. The results of simulating the gripping modes with the simultaneous “skid” formation are presented, and the similar experimental oscillograms are considered. It is shown that with the new control algorithm, the electric drive speeds are closer to their setpoint values. This results in better curvature formation accuracy at lower preset “skid” values. Recommendations for tuning the control system are given.

Автоколебания клетей стана тандема холодной прокатки 2000 Магнитогорского металлургического комбината

One of the problems of cold rolling of thin strips is self-excited chatter vibrations, which lead to the appearance of various defects. High-frequency self-oscillations can lead to defects related to surface quality, low-frequency ones with high amplitude levels can lead to gusts of thin bands or even severe accidents of the rolling mill itself. As a rule, self–oscillations occur suddenly at high rolling speeds, more than 20 m / s and thin strips, the thickness is usually around 300-700 microns. For the normal operation of the rolling mill, it is necessary to use special systems for monitoring the vibration state and preventing the occurrence of self-oscillations. The control system for exceeding the critical vibration level generates signals from the automated control system of the mill to eliminate self-oscillations. The critical vibration level is determined by the spectral composition using the fast Fourier transform (FFT). When self-oscillations occur, lowfrequency components from 5 to 20 Hz prevail, frequencies in the range of the third octave from 100 to 200 Hz and frequencies of the fifth octave from 400 to 800 Hz. The cold rolling mill 2000 of the Magnitogorsk Iron and Steel Works combines a tandem five-cell mill and a continuous etching unit. There is no regular vibration monitoring system at the mill, warning and elimination of self-oscillations occurs in manual mode. With the use of research vibration equipment, experimental studies have been conducted on the possibility of using technological parameters to control and prevent the occurrence of self-oscillations. The moment of occurrence of self-oscillations can be controlled by the vibrations of the hydraulic tensioning device (GNU) of the mill. Processing of the vibration displacement signal of the measuring channel of the GNU FFT

Importance of the integrated manufacturing execution system for a metallurgical enterprise

The object of the study is Manufacturing Execution System. The relevance of the study is conditioned by the fact that the metallurgical industry has been demonstrating a high level of volatility in the global market over the past few years. The issue of the effectiveness of the metallurgical enterprise is directly related to ensuring environmental safety. The purpose of the study is to consider how the Manufacturing Execution System (MES) operates in the metallurgical industry and highlight its features, offering recommendations aimed at improving operational efficiency with the introduction of MES systems at enterprises of the metallurgical industry of the Republic of Kazakhstan. The following methods were used in the study: analysis, synthesis, comparison, graphical representation of data. Using the example of the Magnitogorsk Iron and Steel Works, the study examined the relationship between MES and APCS (Automated Process Control System), highlighted the requirements for the transition from individual management of particular cases of technological rules and restrictions to the digitization of general algorithms. It was defined that the advantages of a production system include its fast payback. Also, it was determined that the MES system allows automating production operations and information support, carrying out operational planning, accounting for production and quality of metal products, tracking the history of each product, managing equipment, and analyzing performance. In addition, the recommendations that can be used as a basis for creating an enterprise development program, increasing the level of productivity, therefore, reducing the cost of the enterprise's products, were developed

Social policy of metallurgical enterprises: the main guidelines

The main task of a modern enterprise is an effective management system that plays an important role in personnel management. Social policy has always been a key policy tool for solving emerging social problems and implementing the company's development strategy. In this article, the author analyzes the main directions of social policy implemented through social programs of the metallurgical industry enterprises: PAO Magnitogorsk Iron and Steel Works, PAO Novolipetsk Steel Works, and PAO Severstal.

Investigation of the Mix Sintering Process in a Dense and Mechanically Loosened Layer on Sinter Machines of Sinter Factory No. 5 of Magnitogorsk Iron & Steel Works PJSC

Investigation of the Mix Sintering Process in a Dense and Mechanically Loosened Layer on Sinter Machines of Sinter Factory No. 5 of Magnitogorsk Iron & Steel Works PJSC

Development of new composition for sHSS steel used for hot rolling mill rolls at Magnitogorsk Iron and Steel Works

The paper presents the results of the complex scientific and research work directed on development of the new composition of sHSS steel for rolling mill rolls together with Magnito-gorsk Iron and Steel Works (MMK) and Magnitogorsk Mill Rolls Plant (MZPV). The first part includes the review of technical literature in the field of the results of roll steel examination by domestic and foreign researchers, investigation of structure and determination of properties of foreign rolling rolls, which were operated at the MMK hot rolling mill. The minimal level od sHSS steel properties for the working layer of a rolling roll, providing its operation reliability, is also determined. Laboratorial experiments were conducted at the second stage. The formed massif of ex-perimental data was processed using neural net, and as a result, the optimal chemical composition of the roll steel with high wear resistance and hardness was obtained. After processing of the re-sults of the planned experiment, the regression equation was obtained; it describes influence of the alloy chemical composition on wear resistance and hardness coefficients. Optimized composition of the alloy was developed at Magnitogorsk Mill Rolls Plant; it wad resulted in manufacture of the pilot roll sleeve in centrifugal machine. This roll sleeve was subjected to heat treatment according to the standard plant procedure. The final step included laboratorial testing of the pilot roll sleeve which was manufac-tured from steel with optimized chemical composition. It was determined that the developed composition is characterized by wear resistance increased by 27 % in comparison with the re-searched foreign analogue, as well as by similar qualitative parameters of the alloy microstructure.

Providing steel with an approximate application of the mechanical properties of wire rod 5.5-6.5 mm from sreel grades 70-75 based on a conventional twin of the Stelmor process

In 2019, the air-cooling line of Mill 170 of PJSC MMK (Magnitogorsk Iron and Steel Works) was upgraded. The main task of modernization was to obtain wire rod sorbitized in the initial state. The use of such products makes it possible to abandon one intermediate heat treatment operation in the wire production process, and should also ensure the stability of the mechanical properties of the finished wire of the entire size range of OJSC MMK-METIZ. On the part of OJSC MMK-METIZ, the following high requirements were imposed on the uniformity of the mechanical properties of the wire rod obtained at the mill - no more than 40 N/mm2 along the length of the convolution, 50 N/mm2 along the length of the coil, 60 N/mm2 within the melt. When analyzing samples of rolled products from steel grades 70-75 with a diameter of 5.5-6.5 mm, it was found that compliance with the requirements in the modes operating at the mill is difficult. By the order of PJSC MMK, as part of scientific research on the development of wire rod production technology using a digital twin of an air cooling line, a mathematical model was developed, the adequacy of which was proved by developing rolling modes based on it, followed by evaluation of the resulting product. Upon further analysis of the obtained rolled products, it was found that the products manufactured according to the new modes meet the requirements for uneven mechanical properties along the length of the convolution and the coil to a greater extent.

Improvement of the methods of sample preparation for metallographic analysis in the conditions of the central laboratory of PJSC MMK

In this paper, the methods of sample preparation of industrial samples for metallographic analysis in the conditions of the Central Laboratory Control of the Magnitogorsk Iron and Steel Works are considered. The method of preparation of grinds using electrolytic polishing with subsequent etching of the surface is proposed. The advantages and disadvantages of existing methods of sampling for metallographic analysis in production are considered. A sequential scheme of sample preparation using grinding machines and an electrolytic polishing unit LectroPol-5 is proposed. The article also proposes to replace the imported electrolyte for electrolytic polishing with a domestic one of known chemical composition. Using a domestic electrolyte significantly reduces the cost of buying an imported electrolyte. Studies of electrolytic polishing modes for low-carbon steel and copper have been carried out. The modes of electrolytic polishing were selected experimentally. The surface was evaluated using an optical microscope.

Analysis of slag mode of blast furnace melting using model decision support systems

The article presents a balance model of the blast furnace process improved by the researchers from UrFU and PJSC “Magnitogorsk Iron and Steel Works” (MMK). It generally represents a system of deterministic dependencies characterizing the thermal, reduction, gas dynamic, blast and slag modes of blast furnace melting. The basic principle underlying the model is full-scale mathematical modeling. Indicators characterizing the properties of the final slag for implementation of normal slag mode of blast furnace melting (slag viscosity in the temperature range of 1350 – 1550 °C, as well as values of the slag viscosity gradients) were proposed. The slag viscosity gradient, along with the acceptable ranges of slag viscosity at different slag temperatures, are used in modeling the slag mode as limiting factors for the diagnosis of slag mode. Selection of the limit values of each of the ranges and the viscosity gradient is carried out by the method of expert evaluation. Structure of the model for calculating the parameters of the final slag is considered. Using a mathematical model of the blast furnace process, analysis of the slag mode of blast furnace melting was performed according to the actual indicators of their operation. It was established that desulfurizing ability of the slag is insufficiently used, as a result of which cast iron of reduced quality is smelted both in terms of content of sulfur and silicon. Change in characteristics of the slag mode, other things being equal, has a positive effect on gas permeability in the slag formation zone, reducing capacity of the gas and productivity of the blast furnace increase, as well as the consumption of coke decreases. The authors describe the results of design calculations of the MMK furnace performance indicators when changing the composition of loaded materials. Recommendations on the slag optimal basicity are given. Calculations showed that the optimal basicity of the final slag, which ensures its maximum liquid mobility, for operating conditions of blast furnaces of the combine is 1.04 – 1.05 for the CaO/SiO2 ratio and 1.30 – 1.32 for the (CaO + MgO)/SiO2 ratio.

Development of a finite element model for calculation of the thermal field of coil rolled products in the thermomechanical process

A finite element model has been developed in the Deform-3D software package for calculating the thermal field of low-alloy steel coil rolled products during rolling in the finishing group of stands and cooling on the discharge roller table of the 2000 wide-strip hot rolling mill of PJSC Magnitogorsk Iron and Steel Works (PJSC MMK). The proposed model takes into account heat release during plastic deformation, cooling of the strip due to metal contact with air, heat transfer to the work rolls, cooling of the strip by water supplied in the process of interstand cooling and in the accelerated cooling unit on the discharge roller table. At the same time, the features of cooling by both upper and lower collectors are taken into account. To achieve the required coiling temperature, the possibility of differentiated activation of collectors of the upper and lower sections of the accelerated cooling unit was implemented, which was introduced into the finite element model. Cooling by water jets was updated by dividing the contact of the cooled strip with water into two zones - the area of water impact with the sheet surface and the area of film boiling. As a result of the analysis of the thermal state of the sheet, an assessment was made of the nature of its change depending on the characteristics of each stage of thermomechanical treatment (TMT). The use of the presented model in the development of TMT technological modes makes it possible to evaluate their correctness, as well as to provide the possibility of predicting the structure and properties formed over the thickness of rolled steel in the process of controlled rolling with accelerated cooling.P. P. Poletskov, S. V. Denisov, P. A. Stekanov, E. V. Braichev, and P. G. Adishchev, post-graduate student of the MTa-21-2 group, took part in the work.The work was carried out at the Nosov Magnitogorsk State Technical University with the financial support of the Ministry of Education and Science of Russia as part of the implementation of a comprehensive project to create high-tech production (Agreement with the Ministry of Education and Science of Russia No. 075-11-2021-063 dated 06/25/2021).

The role of the enterprise's social policy in its development

This article examines the role of social policy at the enterprise and the degree of its importance for the organization and its employees. Staff is one of the components of the enterprise’s internal environment. Therefore, the organization needs a mechanism that contributes to increasing the employees’ motivation for high-quality performance. The internal social policy at the enterprise is an integral part of the employees’ motivation to increased efficiency. Social policy should meet the workers’ needs and interests. Social policy is formed based on the employees’ requests. Social programs at the Magnitogorsk Iron and Steel Works (MMK) are diverse and meet the interests of various groups of employees. These programs include: therapeutic and preventive programs, vouchers to resort houses and vacation retreats, preferential vouchers to camps for employees’ children, formation of healthy lifestyle principles, organization of hot meals for employees, organization of cultural recreation for employees, housing, youth, and educational programs, programs to stimulate natality and support motherhood and large families. Thanks to the educational programs, MMK improves the employees’ knowledge, skills and abilities, which allows producing better products. Also, such social policy allows attracting more qualified workers, which makes the organization competitive in the economic market. The MMK social policy is constantly improved, which contributes to an annual increase in the percentage of the employees’ satisfaction with the social policy. Thus, the MMK internal social policy has been developed based on the employees’ interests and is aimed at meeting the employees’ needs, which, in turn, helps motivate the staff to perform their work and their duties efficiently.