Simulation System of the Metallurgical Plant Nadezhda

Simulation System of the Metallurgical Plant Nadezhda

Development of the simulation system of the metallurgical plant for:

  • metallurgical plant performance evaluation
  • analysis of different production increasing scenarios for the smelting and converting section
  • estimation the capacity of the white matte dispensing section after plant modernization.

Period: June 2022 – November 2022
Industry: Metallurgy
Client / Partner: Norilsk nickel

Project objective

  • Accurately evaluate the performance of the metallurgical plant
  • Analyze different production increasing scenarios for the smelting and converting section
  • Estimate the capacity of the white matte dispensing section after plant modernization

The main stages of work and characteristics of the model

  • Development of the simulation model concept
  • Development and testing the simulation system on the Amalgama platform
  • Verification the compliance of the numerical indicators provided by the system with the corresponding indicators of the real production operations
  • Analysis of plant operation options after modernization using the developed simulation system
  • Conducting training for system users

Model input data

  • Filling rate of the matte of melting furnaces
  • Slag-cleaning furnaces’ working cycles
  • Durations of technological operations in converters
  • Durations of crane operations and transportation by transfer cars
  • Durations of technological containers processing (ladles)

The main structural elements of the model

  • Input data file of scenarios in MS Excel
  • Simulation system which includes scenario editor, operations scheduler, and simulation model with dynamic presentation

Model output data

  • Statistical indicators of plant operations: matte processing rate, white matte production, quantity of shipped ingots, etc.
  • Planned and simulated schedules of main production operations
  • Schedules of crane and transfer car tasks in tabular form

Project result

  • The maximum achievable productivity of the plant after modernization has been determined
  • The choice of the preferred technology of the plant operation has been substantiated
  • It has been determined that the initial production targets were unattainable, even with the selected technology
  • Limitations that would not allow the production targets to be achieved have been identified
  • The required number of technological utensils, including ladles and molds, has been determined
  • Requirements for the modernization of the crane system of the smelting and converting section have been determined