On April 27, the first phase of the CNI nickel-iron RKEF project in Indonesia, undertaken by the International Business Department of Minmetals Twenty-Three Metallurgical Construction, successfully produced nickel-iron, marking the official entry of the project into the trial production phase. Behind this significant milestone was the unwavering perseverance and dedication of the project team, who overcame the "three major challenges" of rotary kiln hoisting, electric furnace construction, and timely iron production over more than 700 days and nights, setting multiple new records for the company in the field of overseas metallurgical construction.
Meticulous
Successful Completion of Rotary Kiln Hoisting
The rotary kiln for the first phase of the CNI nickel-iron RKEF installation project in Indonesia, with a diameter of 5.8 meters and a length of 130 meters, is the core equipment of the RKEF nickel-iron smelting process. Its installation quality directly affects the normal operation of the entire production line. The team innovatively adopted the "segmented pre-assembly + laser positioning" method, controlling the installation accuracy to the millimeter level.
The project department organized multiple discussions, refinements, and revisions of the hoisting plan, developing a safe, economical, and efficient hoisting scheme. At the same time, they fully coordinated with the supervision and construction parties, carefully reviewing each construction phase. Before hoisting, comprehensive inspections were conducted on the crane, ground, slings, and equipment body, and all workers were briefed on safety techniques.
The project began on-site bearing seat grinding in November 2023; in December 2023, the base and support rollers were hoisted, and the cylinder was assembled on the ground; in January 2024, the first section of the cylinder was officially hoisted, and over 1,000 mt of the kiln body was hoisted within one month, completing the aerial welding of the cylinder in just 10 days, setting a new industry record for efficient construction.
Chasing the Wind and the Moon
Ensuring Smooth Progress of Electric Furnace Construction
The rectangular electric furnace involved in the first phase of the CNI nickel-iron RKEF installation project in Indonesia had only been constructed by China Fifteenth Metallurgical Construction domestically, and the furnace for this project was larger in scale and more complex in process. As a key piece of equipment, the construction of the electric furnace required immense effort from the project team. Due to the remote location of the project, material procurement faced numerous constraints. To address urgent material shortages, the project department implemented a multi-point layout strategy, stationing procurement personnel domestically and in Jakarta and Kendari to ensure timely material supply.
During the Chinese New Year, the project team remained on duty, implementing precise strategies and completing the installation of the electric furnace and rotary kiln with high quality. Particularly in key processes such as the refractory brick laying of the electric furnace and the refractory material pouring of the rotary kiln, the work was completed 10 days ahead of schedule, with quality indicators exceeding national standards, laying a solid foundation for the successful start of production of the electric furnace and also filling the company's gap in the field of rectangular electric furnace construction.
On March 7, the 72MVA rectangular electric furnace was successfully started. ENFI, the general contractor of the project, sent a letter of commendation to the project team, praising the project management team for its outstanding professional capabilities and the spirit of overcoming difficulties during the project construction. The letter stated that the team "ensured efficient contract performance through scientific management" and "strictly controlled quality throughout the entire process," and specifically mentioned that "despite the compressed project duration, the construction tasks were completed ahead of schedule, fully demonstrating your company's strength in the field of metallurgical construction."
Pursuing Excellence
Striving to Achieve the Tapping Target
The "April 30 tapping" period target set by the owner was unanimously regarded as "nearly impossible to achieve" by the supervisor and the general contractor. The project department implemented a "two-shift" operation mode and established an "hourly" progress control system. All members worked day and night in a fierce race against time.
Focusing on the goal of tapping on schedule, the project department collaborated with the general contractor, supervisor, and other relevant units to work backwards from the project deadline, subdivide the construction characteristics of each subproject, and communicate and coordinate in advance the supply of personnel, machinery, and material spare parts. From the successful power transmission to the electric furnace on April 6, to the successful slag tapping on April 18, and then to the successful production of ferronickel on April 27, the project team set a record for the company's large-scale rectangular ferronickel electric furnace, taking only 21 days from the start of power transmission to the production of ferronickel. The tapping period was achieved 3 days ahead of the original plan.
Like a boat navigating the vast sea or a horse standing atop Kunlun Mountain, the International Business Department of Minmetals 23rd Construction Group Co., Ltd. will stride forward with the tide of the times, seizing the opportunity to accelerate the construction of a new highland for metallurgical construction under the "Belt and Road" Initiative. Adhering to the development philosophy of cooperation, mutual benefit, and win-win results, the department will introduce more Chinese solutions, technologies, and construction practices to the participating countries.
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