Fast project execution and production ramp-up
The contract for the modernization of the Flash Smelting Furnace No. 1 was signed on 20th October 2014, with delivery of the equipment completed in August 2015. Work on dismantling the old furnace started on 1st September, and the installation of the new equipment were completed 5th of November, when the 15-day furnace heat-up was started. There were held five project meetings and three inspection events at manufacturing shops with customer between December 2014 and July 2015.
The project consisted of 18 supply packages and brought together the following teams during different project stages:
• Engineering: 70
• Installation supervisors from Outotec Finland: 13, Outotec St Petersburg: 9 and from sub-suppliers: 11
• Commissioning team: 8 persons from Outotec Espoo and Pori offices.
The total amount of installation supervision and commissioning services between 15th September and 17th December 2015 came to 1227 man-days.
• 1st September 2015: Shutdown started
• 19th November 2015: Mechanical completion, concentrate feed to the furnace started
• 15th December 2015: Project Final Acceptance Act signed
We are delighted that the project could be successfully delivered within the agreed timescale, with the planned shutdown schedule of 65 days achieved followed by a rapid ramp-up back to production.
Total feed of 260 t/h, which exceeded the design value, was achieved on 27th November 2015 and the 72 hours test-run began on 10.12.2015. All performance guarantee values were demonstrated within the first three day trial.
Norilsk Nickel and Outotec have developed a long and successful relationship working together on such projects. The Nadezhda smelter was originally built in the late 1970’s and commissioned in the early 1980’s. It has preserved its significance as one the major nickel producing sites in the world. Together, the whole mission was conducted in an outstanding manner by firstly setting accurate targets, followed by the necessary studies and tests, through to implementing Outotec industry-leading technologies to achieve the results.
A thoroughly successful project, bringing the warmth of a reinvigorated flash smelter back to the cold Siberian winter.
Text: Kari Pienimäki