Magnitogorsk Iron and Steel Works (MMK) has generated savings of more than RUB 5.5 billion through measures implemented under a programme to reduce coke consumption in blast furnace ironmaking. Since 2024, coke consumption in pig iron production has fallen by 16%.
Launched in August 2024, the programme is part of the Company's Low-Cost Pig Iron strategic initiative, which centres on the operations of MMK's state-of-the-art coke plant No. 12. The commissioning of this high-capacity facility has improved coke quality considerably, with the proportion of dry-quenched coke in MMK's coke production surpassing 70% once coke plant No. 12 reached its design capacity.
The launch of coke plant No. 12 marked an important milestone in MMK's broader programme to reduce coke consumption in pig iron production. In September 2024, a coal and coke research laboratory was put into operation. Its specialists have developed a digital coal database that enables them to carry out theoretical modelling and determine the optimal composition of the coal blend. Extensive coking trials carried out in laboratory ovens have made it possible to identify the most suitable coal concentrates.
The higher proportion of dry-quenched coke, combined with overall improvements in coke quality, has enabled greater natural gas injection into the blast furnace, thereby reducing coke consumption.
"Reducing coke consumption plays a major role in lowering pig iron production costs and brings us closer to achieving our goal of low-cost production and leadership in terms of non-integrated slab production costs. In today's challenging economic environment, improving efficiency across every stage of production strengthens our position in the market despite declining demand," said MMK CEO Pavel Shilyaev.
MMK continues its systematic efforts to improve coke quality in respect of the M10 and M25 mechanical strength indices, which measure coke degradation and abrasion resistance. These indicators play an important role in blast furnace performance, influencing both furnace productivity and coke consumption. In addition, the Company has successfully reduced the ash content in coke, lowered the proportion of the +80 mm size fraction, and reduced the silicon content of pig iron.