Save Over $14,285 Daily! VPSA Oxygen Generation Plant Helps China’s Largest Steelmaker to Cut Costs and Boost Efficiency

On November 28, 2024, the new VPSA (vacuum pressure swing adsorption) oxygen generation unit built by PKU Pioneer for Anhui Changjiang Steel Co., Ltd. (hereinafter referred to as Changjiang Steel) was completed after more than 2 months of intensive construction. Following 2 days of debugging and connection with the existing liquid oxygen supply pipeline system, the VPSA oxygen equipment was officially put into operation on November 30 to supply cost-effective enriched oxygen (12,500Nm³/h, 80%) to 2 blast furnaces (1080m³ and 1250m³), which will significantly reduce the client’s molten iron production costs and enhance its competitiveness in the highly competitive steel market. Following the successful construction of 3 VPSA oxygen unit s for Maanshan Iron & Steel and Meishan Iron and Steel from 2022 to 2023, the project marks PKU Pioneer's 4th collaboration with China Baowu Steel Group Corp., Ltd., representing yet another milestone in deepening the mutual partnership. The total oxygen production capacity of these 4 oxygen plants reaches 61,200Nm³/h, significantly enhancing blast furnace smelting intensity, reducing coke ratio, and lowering the cost per ton of iron.

창장강철을 위해 구축된 새로운 VPSA-O2 플랜트 (12500/80)

Before using PKU Pioneer's VPSA oxygen equipment, Changjiang Steel has a cryogenic air separation capacity of 52,000Nm³/h (with oxygen purity >99.2%). When its 2 blast furnaces operate at high oxygen enrichment rates, the oxygen shortage reaches approximately 10,000Nm³/h, and the user has been relying on purchasing liquid oxygen to meet this demand. However, the local price of liquid oxygen surged from $57 to over $114 per ton due to supply and demand fluctuations, significantly increasing the user’s production costs. VPSA oxygen generation technology is widely applied in steel enterprises, with nearly 100 steel mills having installed VPSA oxygen units to supplement their oxygen production capacity due to the fact that the VPSA 산소 발생 플랜트가 짧은 공사 기간, 신속한 산소 공급을 위한 빠른 기동 및 정지 시간, 낮은 투자 및 유지보수 비용을 가진 간단한 공정, 유연하고 안정적인 운전, 그리고 무인 운전 달성 능력 등 다양한 장점을 가지고 있기 때문입니다. 이러한 배경에서 고객은 비용 효율적인 산소 공급 요구를 신속히 해결하기 위해 VPSA 산소 발생 기술을 우선시했습니다.
Changjiang Steel highly recognized PKU Pioneer's technical expertise and extensive project experience, and the two parties officially signed a cooperation agreement in July 2024. To maximize investment savings and create benefits, the project adopts the maturely used process of oxygen enrichment before the blast furnace blower. The product oxygen is fed into a low-pressure pipeline filled with enriched oxygen and directly delivered to the blast furnace blower inlet using the 15–20 kPa pressure from the out-of-bound area. The oxygen-enriched air after mixture is then compressed by the BF blower and sent to the blast furnace. PKU Pioneer closely cooperated with the client and optimized the process and configurations of utilities, instrument air, cooling water, etc., based on the conditions of the steel mill. After the project was initiated, the client’s Power Plant Department and Technical Improvement Department leaders worked closely with PKU Pioneer to comprehensively advance project implementation. From civil construction and installation to commissioning, the oxygen unit project was efficiently completed in just 73 days, setting a new record for the construction period of PKU Pioneer’s VPSA oxygen generation systems.
According to calculations by the project manager, the oxygen production cost of a single set (6,250Nm³/h, 80%) of the VPSA-O2 plants provided by PKU Pioneer is approximately $0.03/Nm³, with a daily production cost of only $7200. Compared to the client's air separation unit cost ($0.05/Nm³), it saves $0.02 per Nm³, amounting to a total daily saving of about $5,143. In contrast to the price of purchased liquid oxygen ($0.1/Nm³), the VPSA oxygen generation system will allow the client to save over $14,285 per day, directly reducing liquid oxygen costs by more than 70% and the overall setup investment could be recovered in only 1 year.
VPSA(진공 압력 변환 흡착)/PSA(압력 변환 흡착) 산소 발생 기술의 글로벌 선두주자인 PKU Pioneer는 전 세계 철강 산업에 약 80기의 대규모 및 초대규모 VPSA 산소 발생 시스템을 고효율 및 신뢰성으로 납품하여 철강 기업의 용광로, 전기로, 철강 압연 가열로 납, 구리 및 안티몬 가마의, and converter blowing in steel enterprises. The oxygen production capacity of a single set of PKU Pioneer’s VPSA oxygen generation equipment has exceeded 100,000Nm³/h, with an average specific energy consumption of 0.30±0.02 kWh/Nm³ (converted into pure oxygen production). Leveraging its leading technological advantages and strong innovation capabilities, PKU Pioneer also continuously expands the industrial applications of VPSA/PSA oxygen generation technology. It has successfully delivered over 300 high-efficiency oxygen generation solutions to more than 20 industries, including non-ferrous metallurgy, glass, fiberglass, batteries, cement, waste incineration, and chemistry (such as soda ash and SO? production). Looking ahead, PKU Pioneer will continue to collaborate with more clients to drive industrial production toward low-carbon, environmentally friendly, and cost-efficient development.