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Novokramatorsky mashinostroitelny zavod (NKMZ) has completed the production of a mine winding machine МПБ-5х2.5х2.5.

Its distinctive feature is represented by the brake located inside the drum. This made it possible to fully use the outer cylindrical surface of the drum for winding the rope, thereby increasing the rope capacity for the preset drum dimensions. The machine has self-adjusting shoe brakes, which are fully balanced and neutral to the direction of rotation of the drum. The spring-pneumatic, load-free brake drives are also applied. To ensure easy installation and maintenance, the brake and actuators were mounted on swing frames. Such a compact design of the braking system made it possible to significantly simplify the configuration of the foundation and achieve a reduction in its size, which will further reduce costs during the construction of the winding unit building.

Press relations service of NKMZ

Owing to its unique technological capabilities, Novokramatorsky mashinostroitelny zavod (NKMZ PJSC) is known as manufacturer of big as well as complicated and precise machinery, equipment and components.

In June, the company completed the manufacture of a large-sized assembly unit – a blast furnace casing. It consists of four, installed one on top of the other, shells – three conical and one cylindrical, with a diameter of 12-14 m. The height of the entire casing is 9 m, the weight is 160 tons. This is the third such casing made by NKMZ workers.

Thanks to the use of a unique machine from Haeusler, when rolling the sectors of tapered shells with such a large diameter and sheet thickness of 70 mm, the NKMZ workers managed to ensure the dimensional accuracy of the finished part up to 5 mm. Then the finishing machining of the folded sectors was carried out with a high-precision up-to-date boring CNC machine from Skoda. Here, the most difficult operation was the machining of the areas for the installation of cooling beds.

The casing is the main bearing element of the blast furnace, the purpose of which is to ensure the constructional strength of its structure. It is lined with appropriate refractory materials. In addition to the pressure caused by the processes occurring in the working volume of the blast furnace, the casing is subjected to loads from the weight of the blast furnace top charging equipment, gas outlets, platforms and other structures.

Press relations service of NKMZ

In May, the rolls and power generating equipment production division of the Novokramatorsky Mashinostroitelny Zavod shipped to the customers about 180 mill rolls with a total weight of over 1,500 t, weight range from 1 to 40 t. These are backup and work rolls, idle and driven rolls, top and bottom rolls, intermediate and vertical rolls.

Some of the products were shipped to the metallurgical enterprises of Ukraine: Nizhnedneprovsky Tube Rolling Plant (Dnepr), Kramatorsk Metal Rolling Plant, Interpipe Niko Tube (Nikopol); to iron and steel works – MMK named after Ilyich and Azovstal (Mariupol), Zaporizhstal, ArcelorMittal Kryvyi Rih. More than half of the total mill rolls volume has been shipped to regular customers from Turkey, Slovakia, India, France, Czech Republic, Romania.

Rolling mill rolls are the most popular nomenclature of NKMZ. The enterprise produces four types of them – backup hot rolls and backup cold rolls, work hot rolls and work cold rolls.

Rolls of the NKMZ brand are successfully operated by metallurgical enterprises from 43 countries of the world, on four continents. Throughout its history, NKMZ has produced more than 1,3 million tons of various mill rolls.

Press-service of NKMZ

The Novokramatorsky Mashinostroitelny Zavod designed and manufactured a complex of equipment for a small-section wire mill 350/250.

This is a modern universal highly automated mill for the bars (Ø10-30 mm) and wire rods (Ø5.5-12 mm) production in coils from various steel grades and titanium alloys.

The equipment of the new mill includes:
• section of a continuous train of horizontal and vertical stands 350 for the bars production,
• section of a continuous train of horizontal and vertical stands 250 for wire rods production,
• wire rod coiling section,
• energy sources systems, electric drives and automated process control systems,
• software.

“In the past NKMZ mainly carried out the modernization and reconstruction of mills of this type, manufacturing separate equipment for them, but for this project we have manufactured the entire mill, – says Dmitry Morozko, chief designer of the design department of NKMZ rolling mill equipment production division. – It is very important that for the 350/250 small-section wire mill, the Novokramatorsk employees, together with the engineering and equipment production, carry out a complete supply including rolling technology and software product. It should also be noted that at this mill we have provided the rolling of a fairly wide range of steel grades and alloys. Among them are carbon, structural, alloyed, corrosion-resistant, heat-resistant, oxidation-resistant, high-speed steels, as well as titanium alloys. Since they all require different values of force and rolling temperature, as well as different reduction (degree of metal deformation), then, as a rule, they are not rolled on the same mill. And the Novokramatorsk employees have created a universal mill with such capability. At the same time, our mill also differs from the mills of this type, which are operated by metallurgists today, by a high level of automation”.

Press-service of NKMZ

Novokramatorsky Mashinostroitelny Zavod (NKMZ) shipped to metallurgists of OJSC “Uzmetkombinat” (Bekabad, Republic of Uzbekistan) a modern ladle turret of a new design for a continuous casting machine (CCM). Even with a rather tight delivery time for this equipment determined by the customer, due to the optimal organization of production, the plant’s employees managed to ensure its early production.

The new turret will be installed in the place of its morally and physically obsolete dismantled predecessor. The start of installation work is planned immediately after its delivery to the customer in July of this year.

The turret for NKMZ is not only a jubilee one, but also a unique one. Its uniqueness is in its mobility. It will be installed on a self-driven roll-out platform (pictured), which will move it five meters away from the casting axis.

At the beginning of April, Uzbek metallurgists participated in the intermediate acceptance of the stand and were completely satisfied with its work during control tests in the workshop of our enterprise. They noted that they were not mistaken, choosing NKMZ as the turret manufacturer, and talked about the possibility of our further cooperation.

Press-related service of NKMZ

At the Novokramatorsky Mashinostroitelny Zavod, the issuance of documentation for the modernized cone crusher for coarse crushing with hydraulic adjustment of the slot model KKD1500x180 GRSH-M for Mining-and-Processing Works of Poltava has been completed. It is now under construction. As a result of the improved design of the crusher, its productivity will increase to 5.5 thousand tons/hour, which is 55% higher than that of the crusher used before.

In a cone crusher, material is crushed by compressing it between two armor profiles. One profile is set by the armors of the cone, the other by the crushing bowl. During their gyratory motion (complex rotation in several planes), the material is ground under constant compression.

The plant’s specialists already produced cone crushers of this standard size, but only of standard performance. Last year, such a crusher was manufactured and supplied to Mining-and-Processing Works of Ingulets, and today it is being installed at the customer’s site.

The peculiarity of the new modernized crusher is that at the request of the customer, it will be installed instead of the worn out and dismantled predecessor on the available foundations.

While maintaining the overall dimensions of the new crusher, its higher productivity will be ensured due to the improvement of the design of units performing material crushing, as well as an increase in the drive power. So, the profile of the armor, the profile of the crushing chamber and the main units on which the armor rests have been modified. The cone swing frequency became higher.

Press-related service of NKMZ

The next, third casing of the blast furnace is being manufactured today by NKMZ, using the unique technological capabilities of the equipment which is installed in the workshops of the enterprise.

The casing is the main supporting body of the blast furnace. It is lined with appropriate refractory materials that make it possible to smelt cast iron in it.

The casing, which the NKMZ workers are making today, is a massive and large-sized structure, consisting of four shells installed on top of each other – three conical and one cylindrical. Their diameter is 12-14 m, the total height of the casing is 9 m and the total weight is 160 tons.

In the manufacture of tapered shells, the first most difficult task is to ensure their rather strict geometric dimensions during the segments’ rolling process. So, with a finished part diameter of 12-14 m and a sheet thickness of 70 mm, an accuracy of up to 5 mm is required. This task is solved in workshop No. 16 thanks to the use of a unique Haeusler machine, which allows rolling large shells of great thickness with high accuracy. And then in the machining-assembling shop No. 8 on a high-precision up-to-date boring machine with CNC from the Skoda, the finishing machining of the rolled segments is carried out. Here, the most difficult operation is to machine the places for the installation of cooling beds.

Today, the first stage of manufacturing of the third casing has been completed: four shells have already been finished in workshop No. 16. Soon they will be disassembled into segments and passed for machining.

Press relations service of NKMZ

NKMZ PJSC has started manufacturing of a unique overhead ore double grab car reloader for Azovstal Iron & Steel Works.

In recent years, NKMZ has manufactured, shipped and installed several coal grab reloaders for coal warehouses, including for Azovstal, as well as one ore reloader for the ore stock yard of PJSC Zaporizhstal.

“The uniqueness of the new reloader is provided by several characteristics,” says Sergey Martynenkov, deputy chief designer of chief designer department of the mining and press-forging equipment division at NKMZ. – These are gigantic dimensions: the span or the distance between the supports is 115 m with a total length of the beams of 185 m, the height is 49.7 m. It also has a significant weight – 2400 tons. But its main advantage is high productivity, which is achieved by the presence of two grab cars moving independently of each other. They will ensure a total capacity of this machine – 800 t / h. On the previous NKMZ reloaders, only one grab car was used.

The contract for the manufacture of this reloader was signed by NKMZ with Metinvest in 2019. The active phase of its production began in March this year. As of today, the necessary design and technological documentation has been issued for production. The production of a rigid support for the reloader and a mechanism for its movement, which includes 24 gearboxes, 96 traveling wheels and a system of balancing bogies, is already in progress.

The beginning of the installation of the reloader at the Azovstal Iron & Steel Works is scheduled at the end of this year, and commissioning – at the end of the next year. ”

Press relations service of NKMZ

At Novokramatorsky Mashinostroitelny Zavod a modern ladle turret of a new design was presented to the customers – metallurgists of JSC “Uzmetkombinat” (Bekabad, Republic of Uzbekistan).

Having looked at the work of the ladle turret, the Uzbek specialists were completely satisfied with it. As a result, an intermediate acceptance certificate was signed.

NKMZ has wide experience in the design, manufacture and replacement of ladle turrets of all types and various capacities. For almost twenty years, the enterprise has manufactured and delivered 19 such ladle turrets for metallurgists of Ukraine, Europe and Russia, each of them has certain peculiarities. The highlight of this 20-th ladle turret is mobility.

Another feature of this contract is that the customer has determined a rather tight time frame for the delivery of equipment, while the specialists of NKMZ managed to finish its production prior to the scheduled date.

Vladimir Chibishev, Deputy Head of the Electric Steel Smelting Shop for Mechanical and Power Equipment of JSC “Uzmetkombinat” shared the first impressions of the new ladle turret.

“The brainchild of the specialists of NKMZ is impressive. I think we were not mistaken in choosing the ladle turret manufacturer. As a specialist, I have been to many enterprises in the post-Soviet space. In comparison with them, NKMZ surprises with its large capacities and high potential. Your company has a great future.
The Uzbek Metallurgical Plant plans to increase production capacity, modernize and upgrade equipment. I think that we will find a common language with NKMZ in terms of further cooperation”.

Andrey Tsarev, Chief Designer of the Design department, Metallurgical and sinking equipment division of NKMZ, tells about the specifics of this contract.

“When concluding the contract, we managed to win in a tough competition, because in the process of preparing it we worked closely with the technical specialists of the Uzmetkombinat, and in the new ladle turret we tried to implement all the solutions they needed.

It has two independent lifts, the lifting capacity of each joist is about 200 tons. All ladle turrets previously manufactured by NKMZ were installed permanently. And this one will be installed on a rolling-out platform that has its own drive, which will move it at a distance of five meters from the casting axis. The need to move the ladle turret arose due to the impossibility of assembling it in the aisle space of the workshop, where it will be finally installed.

Previously, we already worked with the Uzbek Metallurgical Plant, now we have resumed our partnership. Now we are participating in a tender for the supply of a pump-and-accumulator station for the same Continuous Casting Machine. In the future, we will participate in the tender for the reconstruction of the CCM as a whole.”

The advantages of NKMZ ladle turrets in comparison with ladle turrets of other manufacturers are that more than 20 patents have been obtained for the new design solutions used in them. This circumstance allows them to be much more attractive in comparison with similar products of competitors on the market for this equipment.

Novokramatorsky Mashinostroitelny Zavod plans to ship three 15-ton rotor shafts to General Electric (USA) in the second quarter of 2021.

“NKMZ has been working with the GE Oil&Gas division of General Electric since 2013. At that time, our company was certified as a supplier of full-cycle finished machined parts for GE Oil&Gas, a global manufacturer of generators and electric motors for pumping gas and oil.

During this time, NKMZ has manufactured more than 3 thousand tons of products for GE Oil&Gas. Today, our strategy is aimed at further increasing the number of supplies – says Mr. Stanislav Zakharchuk, head of the rolls and power generating equipment laboratory.

The rotor shaft is a critical part, to which very high requirements are imposed on processing accuracy – value of the total mechanical runout, reflecting all the defects of its shape, should not exceed 9 microns.

Specialists of “General Electric” have developed a special technique for measuring the defect in the shape of the shaft bearing necks – runout, out-of-roundness, triangulation – with several sensors in several planes. Specialists from the rolls and power generating equipment division developed tooling and purchased the necessary equipment for this technique to ensure high accuracy of measurements.

Prior to machining, the rotor shaft blank had been subjected to a special heat treatment cycle to obtain fine and uniform grain in the metal structure, which will subsequently provide low electrical runout values, which means a low vibration when the rotor rotates in the electric motor.

The representative of the French branch of General Electric, David Thomas, carried out an expert assessment of the implementation by our specialists of the measuring technique for mechanical and electrical runouts of the rotor shaft bearing necks and gave a high assessment to the quality of machining at NKMZ”.