The remaining refractory thickness assessment of hearth part. It should be operated not less than 15 years during one campaign. Furthermore, because the power input is not limited by the. Different part of blast furnace features different nature of refractory lining wearing. Pdf the byproducts of coke dissolution in iron are primarily calcium aluminate minerals known as coke ash. Refractory bricks used for different parts of blast furnace. Pdf a study on castables refractories used in blast furnaces runners is.
Campaign life of furnca ehave increased from 5 yrs 1020ye and more these days. Blast furnace bosh design and repairs page 1 of 15 b2045 1. Design of blast furnace crucibles by means of the nodal wear model. The frequent maintenance is basically the effect of high corrosion and erosion of working lining castable. Blast furnace refractories blast furnace lining refactory.
An emergency internal high temperature inspection of the dome was conducted the following day and. The purpose of a blast furnace is to reduce and convert iron oxides into liquid iron called hot metal. For blast furnace whose volume is smaller than m3, we can use aluminum carbon brick. Furnaces and refractories fusion dust and slag or by the action of alkalies on fireclay refractories, to form alkalialumina silicates. Refractory systems iron and steel industry steulerkch. The dedicated team consists out of blast furnace technicians, metallurgists and ceramic engineers all having long experience in blast furnace technology and refractory applications. With todays large blast furnaces, the main trend in hotblast stoves is toward high temperature and. High temperature top combustion hot stoves of kalugin. High temperature top combustion hot stoves of kalugin design for blast furnaces b. The furnace is cooled with water running inside part of the case and bricks. Pelletizing a pellet plant contains a series of balling drums where the iron ore concentrate is formed into soft pellets, in much the same manner that one rolls a snowball, to make a pellet about the size of a marble between 14 and 12. How to choose refractory bricks used for different parts of.
As with the 2dmodel, the size and shape of the 3dmodel is modelled according to a real life blast furnace. The period of the blast furnace operation is limited by the life of the furnace hearth life. The first attempts at wpi were made at the bremen steel works in 1994, with commercial injection starting a year later. From top to down a blast furnace is divided into throat, upper stack, middle stack, lower stack, belly, bosh, hearth and bottom. Best blast furnace refractory for sale in rongsheng manufacturer. The first integrated system for injecting plastic wastes was at. Any material expands when heat ed, and contracts when cooled. Coke is the most important raw material fed into the blast furnace in terms of its effect on blast furnace operation and hot metal quality.
As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. Dcarc, furnace, reverberatory, blast, copper, lead, slag, nickel laterite, chrome, magnesia. Early deterioration of the bosh can influence the operations and potential future production levels. Ofurnace dust enters between gasket and furnace shell and into compensators ocompensator fills with dust and locks stave movements oweld of pipe to stave body fails in fatigue owater leaks into furnace. Consider comprehensively the factors for damaging the furnace lining according to the work environment in glass furnace such as chemical corrosion, mechanical erosion. Pramod kumar bhagat in partial fulfillment of the requirements for the award of master of technology degree in mechanical engineering with specialization in thermal engineering at the national institute of. One way how to intensify the process and reduce the production costs is the prolongation of the blast furnace campaign, which signi. High temperature top combustion hot stoves of kalugin design. Placed inside the carbon lining the concept of the sg ceramic cup is an example where a specific advanced design and material quality render significant benefit to blast furnace operators in terms of lifetime extension and operational efficiency. Simple 3d geometry figure 3 shows the geometry that is used for setting up the 3d cfd model. The forging furnace is used for preheating billets and ingots to attain a forge temperature. Typical blast furnace internal hearth 3d geometry no refractory visible.
The typical campaign life of a modern blast furnace is 15 to 20 years, depending on the cooling and refractory design as a whole and the hearth area in particular. The primary aim for any blast furnace is to minimize the loss in production by reducing the downtime. They have thick steel sides, lined with refractory bricks, to ensure that heat is not lost. Forging furnaces use an open fireplace system and most of the heat is transmitted by radiation. Up to today, lining materials have been supplied to about 50 blast furnaces in italy and abroad always achieving excellent results and acquiring a solid reputation among the users. It was one of only a few blast furnace refractory suppliers appointed by the metallurgical department of china. The iron ore concentrate is now mixed and ready for the pelletizing process. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. Pdf technological changes in blast furnace iron making in. One of the attributing factors for higher downtime of furnace is the frequent maintenance of trough refractory working lining. In the furnace hot metal, along with slag is processed from the raw material which gets collected in the hearth and blast furnace gases come out of blast furnace from the top. Blast furnace refractory lining campaining life starting of blast furnace to shutting down of blast furnace depend on the life of refractory lining which liesa between the inside working volume to that of outer steel sheel, which protects the steel sheel. Blast furnace has the advantages of large output, high productivity and low cost, which is unmatched by other ironmaking methods.
In the furnace, hot metal along with slag is processed from the raw material which gets collected in the hearth and blast furnace gases come out of blast furnace from the top. Iron making solutions to extend blast furnace lifetime. The refractory bricks are produced in the great many shapes required for the correct lining of each. Plasma furnaces have been successfully applied to the production ofa variety ofmaterials, particularly ferroalloys.
Summart the initial design of the blast furnace bosh is important as it will play an integral part in determining the condition of the bosh as the furnace campaign progresses. A blast furnace is a vertical furnace used for iron making. Analysis of blast furnace liningcooling systems using. The typical load is 5 to 6 ton with the furnace operating for 16 to 18 hours daily. The three dimensional model of heat transfer of cooling stave with refractory lining in a blast furnace are. The main refractory lining of blast furnace hearth is composed by carbon. In the steel industry, the blast furnace is a process for making molten iron by melting iron ore. Service property for refractory is the key effect on the life of blast furnace. In order to protect that material from the pig iron, steulerkch provides lowiron, high temperatureresistant fireclay and andalusite grades for the ceramic cup of the blast furnace along with higractory sintered. The remaining refractory thickness assessment of hearth part in the blast furnace. Traditional refractory materials for blast furnace hearth lining are mainly composed of carbon bricks and the ceramic cup. Torpedo ladles must ensure safe transport of the pig iron from the blast furnace to the steelworks. More than 10 years, shengiron provide quality products and project services for our clients within the iron, steel and nonferrous industries.
Extending blast furnace hearth life metec congress 2019. Each year, the company produces over 60,000 metric tons of refractory materials. Metallurgy and material science, fuel, furnace and refractory. Metallurgy and material science, fuel,furnace and refractory. A typical blast furnace may be up to 32 metres in height and 10 metres in diameter. A blast furnace is usually built with a steel case and bricks made of magnesium oxide or other refractory material inside the case. Technological changes in blast furnace iron making in india since last few decades article pdf available in international journal of science and research ijsr 212. Therefore, selection of refractories for hot blast stoves depends primarily on their creep resistance properties, bulk.
The surfaces of the refractory facing the combustion chamber of the furnace or. Principles for blast furnace refractory lining inspection and. Our group of companies sees its mission in the providing of. All of these developments have helped result in lower iron costs, increased blast furnace campaign life and improved working conditions for operational and maintenance personnel. Owater channel isolated stave gets hotter oeventually furnace shell gets hot and cracks occur nonfixed connection stave moves. Injection of coal and waste plastics in blast furnaces 5 commonly carried out, with only a few ironmaking plants in japan and europe currently injecting plastics. We are present in over 100 main runners, we are plugging over 65 tap holes, and we have made around tens of blast furnace repairs over the. During the operation of a blast furnace cyanides form in the furnace gases which during shortterm stoppages get into the hotblast tract and the.
A high quality coke should be able to support a smooth descent of the blast furnace burden with. Pdf blast furnace hearth refractory and coke ash interactions. C, blast temperatures of 1250 1400 c, and furnace pressures of 3 5 kgcm2. Hotblast stove, apparatus for preheating air blown into a blast furnace, an important step in raising the efficiency of iron processing. Injection of coal and waste plastics in blast furnaces. Generally, adopt high alumina bricks, fireclay bricks and common carbon brick to build blast furnace lining, which results the short furnace life. Pramod kumar bhagat in partial fulfillment of the requirements for. Provides a large variety of refractory products together with the best value which include blast furnace construction materials such as taphole brick, tuyere, linings for shaft, belly, bosh, bottom, and also consumable materials such as taphole clay, trough castable, and furthermore include refractory construction materials for hot stove. During the first lining of the blast furnace 2, the refractory brickwork was renewed and all. Blast furnace simple english wikipedia, the free encyclopedia.
Today, fangyuan group ltd operates the largest carbon block production facility for blast furnace linings in china. Preheated air was first used by james beaumont neilson in 1828 in glasgow, but not until 1860 did the englishman edward alfred cowper invent the first successful. The refractory materials and refractory bricks used in diffreent parts of blast furnace are as follows. Allied mineral products, formerly riverside refractories, offers a variety of mixes including, gunning, pumping, and shotcrete, for the blast furnace. A world class blast furnace operation demands the highest quality of raw materials, operation, and operators. Hot blast stove, apparatus for preheating air blown into a blast furnace, an important step in raising the efficiency of iron processing. With todays large blast furnaces, the main trend in hotblast stoves is toward high temperature and pressure ventilation with dome temperature around 1550. Application of carbon composite bricks for blast furnace hearth. The furnace temperature is maintained at around 1200 to 1250 oc. By malik mubashir university of the punjab lahore, pakistan 2. Our engineers and application technicians will be glad to advise you in the selection of suitable refractory materials for your special areas of application. The bottom of the blast furnace, the hearth, is lined with multiple layers of carbon brick.
The blast furnace body is a huge structure of 50m in height, 20m in width. They have the advantage ofallowing the direct use offine feed materials. Dependence of zinc content on particle size compared to a dustcatcher the shape of a cyclone is much thinner and smaller. For those three parts, we should choose refractory materials with properties of thermal shock resistance, slag erosion resistance and erosion prevention. Application of refractory materials for furnace refractory materials for glass furnace. This is to certify that the thesis entitled, optimization of refractory lining used in blast furnace submitted by mr. The hot blast system, incorporating either three or four hot blast stoves per blast furnace, is the other major refractory installation in the blast furnace complex.
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