Transcript design features of indian blast furnaces

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MECON LIMITED
DESIGN FEATURES OF
INDIAN BLAST FURNACES
Authors:
1.
2.
3.
4.
K
S
S
A
R Pal Chaudhuri, GM, MECON
K Verma, Jt GM, MECON
K Bhattacherjee, DGM, MECON
Mondal, AGM, MECON
Presented by: S Sengupta, DGM, MECON
MECON LIMITED
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Abstract
We have attempted to highlight the design features of Indian BFs
and bring out the “Technology Status” of existing as well as
proposed BF installations both in the large & mini sectors to
provide an insight to the operators as well as entrepreneurs.
Some of major highlights of the paper includes:
•
Technological features of modern Indian BFs
•
Design features and pre – requisites of modern Ironmaking
•
Important BF design and operating parameters
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Effect of various parameters on productivity & coke rate
•
International benchmarks
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The Indian scenario
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BF Technology Vs Alternative Ironmaking Processes
BF technology for Ironmaking will continue to dominate owing to
various reasons:
•
Corex – Finex - Hismelt have only reached commercial stage
•
Investment in alternative processes has elevated business risks
•
Expansion plan under National Steel Policy necessitates adding
large production modules through proven BF route
•
Upgradation and modification of existing BFs
•
Impovement in performance of BFs in terms of productivity, cost
& environmental friendliness
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Major Recent Greenfield & Brownfield Projects of India
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TATA Steel G & H Blast Furnaces
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Bhilai Steel Plant, BF No. 7
Bokaro Steel Plant, Blast Furnace No. 2
Rourkela Steel Plant, Blast Furnace No. 5 (commissioned)
ISP (IISCO) Steel Plant, Blast Furnace No. 5 (commissioned)
Bhilai Steel Plant, Blast Furnace No. 8 (under advanced stage of
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execution)
JSW Steel Limited, Blast Furnace No. 2, 3 & 4 (all commissioned)
Bhushan Power, Blast Furnace No. 1 & 2 (under execution)
Bhushan Steel Limited, Blast Furnace No. 1 & 2 (under commissioning)
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Some Broad Details of Major Modern Indian BFs
Technology
Supplier
Client
Major Technical Data
Remarks
Tata Steel, BF # H
(commissioned 2008)
Tata Steel, BF # I (under
design & erection)
Paul Wurth
RINL, BF # 3
(under commissioning
trials)
Useful Volume: 3814 m3
Number of Tuyeres: 34
Hearth Diameter: 13.0 m
Production: 2.5 – 2.8 Mtpa
(7150 tpd for Bhushan & Tata BF #
H has crossed 10,000 tpd)
Cooling System: Copper staves
SGP - PW INBA system
GCP - PW Annular Gap Scrubber
TRT - 13.5 MW (design)
Top charging - PW BLT system
Hot blast system - PW design
PCI system - PW design
Useful Volume: 4161 m3
Number of Tuyeres: 38
Hearth Diameter: 13.6 m
Production: 2.8 Mtpa (8000 tpd)
Cooling System: Copper staves
SGP - Rasman Screw type
GCP - Bischoff Annular Gap
system
TRT - 14 MW (Mitsui & Nico)
Top charging- PW BLT system
Hot blast system - Danieli Corus
PCI system – CISRI/NMT/SPCL
Bhushan Steel, BF # 2
(under
construction)
POSCO e & c
ISP, New BF
(commissioned in Nov
2014)
MECON LIMITED
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Some Broad Details of Major Modern Indian BFs
Technology
Supplier
Client
Major Technical Data
Remarks
Tata Steel, BF # G
(Revamped in 2005)
Useful Volume: 2648 m3
Number of Tuyeres: 30
Hearth Diameter: 11.05
Production: 1.8 Mtpa (5150 tpd)
Cooling System : Copper staves
Double cast house
PW BLT system
PW GCP (Tangential cyclone +
two stage venturi
scrubber)
Danieli Corus BV
RSP, BF # 5
(commissioned in 2013)
Useful Volume: 4060 m3
Number of Tuyeres: 36
Hearth Diameter: 13.2 m
Production: 2.8 Mtpa (7984 tpd)
Cooling System: Copper plate
coolers
SGP - DC Dewatering Wheel
GCP – DC Bischoff system
TRT - 14 MW (design)
Top charging - PW BLT system
Hot blast system - Danieli
Corus
PCI system - Danieli Corus
Siemens VAI
JSW Steel (BF # 3 & 4)
(BF # 3 commissioned 2009
BF # 4 under
commissioning)
JSPL, Patratu (under
construction)
Useful Volume: 4019 m3
Number of Tuyeres: 36
Hearth Diameter: 12.6 m
Production: Presently ~ 8000 tpd
Cooling System: Copper staves
Paul Wurth
m3
Paul Wurth
BSP, BF # 8
(under advanced stage
of execution)
Useful Volume: 4060
Number of Tuyeres: 36
Hearth Diameter: 13.4 m
Production: 2.8 Mtpa (8400 tpd)
Cooling System: Copper staves
SGP - SVAI RASA system
GCP - SVAI system
TRT - 14 MW (design)
Top charging - PW BLT system
Hot blast system - SVAI design
PCI system - SVAI design
SGP - PW INBA system
GCP - PW Annular Gap
Scrubber
TRT - 14 MW (design)
Top charging - PW BLT system
Hot blast system - PW design
PCI system - PW design
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Some Broad Details of Major Modern Indian BFs
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Technology
Supplier
Paul Wurth
Paul Wurth
Client
Major Technical Data
BPSL, BF #2
(under advanced stage
of execution)
Useful Volume: 1701 m3
Number of Tuyeres: 24
Hearth Diameter: 8.7 m
Production: 1.33 Mtpa (3800 tpd)
Cooling System: Copper staves
SGP - PW INBA system
GCP - PW Annular Gap Scrubber
TRT - 6 MW (design)
Top charging - PW BLT system
Hot blast system - PW design
PCI system - PW design
BSL, BF # 2
(commissioned – 2010)
Useful Volume: 2585 m3
Number of Tuyeres: 28
Hearth Diameter: 10.2 m
Production: 4500 tpd
Cooling System: Copper staves
SGP – Under Implementation
GCP - PW Annular Gap Scrubber
TRT – Not provided
Top charging - PW BLT system
Hot blast system – Existing modified
PCI system – Chinese design
Useful Volume: 2355
Number of Tuyeres: 24
Hearth Diameter: 9.75 m
Production: 1.5 Mtpa (4430 tpd)
Cooling System: Copper staves
SGP – Existing Russian system
GCP - PW Annular Gap Scrubber
TRT – Not provided
Top charging - PW BLT system
Hot blast system – Existing Russian
design
PCI system - DC design
Useful Volume: ~ 3800 m3
Number of Tuyeres: ~ 32
Hearth Diameter: ~ 12.5 m
Production: ~ 2.6 Mtpa (~ 7500 tpd)
Cooling System: Copper staves
SGP – Existing Russian system
GCP - SVAI Annular Gap Scrubber
TRT – Existing System retained
Top charging - PW BLT system
Hot blast system – Existing Russian
design (proposal for up
gradation)
PCI system – Being implemented
m3
Danieli Corus
BV & MECON
Limited
Siemens VAI
Remarks
BSP, BF # 7
(commissioned – 2007)
RINL, BF # 1
(under commissioning)
MECON LIMITED
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Some Broad Details of Major Modern Indian BFs
Technology
Supplier
Danieli Corus BV
&
MECON Limited
Client
JSW, BF # 2
(commissioned)
Major Technical Data
Useful Volume: 1681 m3
Number of Tuyeres: 20
Hearth Diameter: 8.4 m
Production: 1.25 Mtpa (3625 tpd)
Cooling System: Copper plate
coolers
Remarks
SGP - DC Dewatering Wheel
GCP – DC Bischoff system
TRT - Not envisaged
Top charging - TOTEM BRCU system
for Jindal & PW BLT system for
Bhushan
Hot blast system & PCI system –
Danieli Corus
Apart from above medium to large size BF installations,
entrepreneurs in MBF Sector are also increasingly adopting
modern BF cooling system, Bell Less Top (BLT), high capacity cast
house equipment, high temperature stoves including Top Fired
Stoves, coal injection system & use of higher percentage of
prepared burden are being increasingly preferred.
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Modern Ironmaking Practices
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Improved cooling system and refractory design alongwith optimum
instruments
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Proper burden distribution for proper central working, permeable
deadman and reduced heat loss
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High hot blast temperature and high top pressure BF operation
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Nitrogen lean operation i.e., oxygen enrichment upto 4 – 6 %
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Probes and instruments, particularly for controlling large BFs
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Improvement in raw material qualities w.r.t. chemistry, consistency,
granulometry & ratio of prepared burden
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Provision of facilities for pollution control and environment friendly
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Important BF Design/ Operating Parameters
Some important BF design/ operating parameters affecting plant
campaign life and its productivity are:
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High BF top pressure
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High hot blast temperature
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BF top charging equipment
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BF refractory & cooling system
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Stock house configuration & charging system
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Raw material quality
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Auxiliary fuel injection
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Instrumentation & Automation
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Energy monitoring and pollution control measures
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Heat Load Fluctuation w.r.t Type of Operation & Burden Mix
Following table provides insight on peak heat load conditions
alongwith typical heat load fluctuations (oC/ min)
Type of operation
Burden mix
Productivity on
Working vol.
Peak heat load
KW/m2
Heat load
Fluctuation
(°C/min)
Low productivity
Iron Ore lump
< 1.5
10 – 40
6 – 10
Medium productivity
Lump + Sinter
1.5 – 2.2
25 – 95
15 – 50
Medium productivity
Lump + Sinter
1.5 – 2.2
50 – 190
35 – 70
High productivity
> 80% Sinter + <
20% Lump
2.2 – 2.7
70 – 250
50 – 105
High productivity
> 30% Pellet + 50%
Sinter +
Balance Lump
2.2 – 2.7
100 - 450
100 – 190
In consideration to high productivity & long campaign life
requirement, use of copper staves/ plates in contamination free
closed loop soft water circuit alongwith compatible good quality
refractory is desirable
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Effect of Various Parameters on BF Productivity & Fuel Rate
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Sl. No.
1.
Item (Parameters)
Hot Blast Temperature
Base
Value
Change
Productivity
Coke Rate
700 – 900 ° C
+ 100 0C
+3%
3%
900 – 1000 ° C
+ 100 0C
+2%
 2.5 %
1000 – 1100 ° C
+ 100 0C
+ 1.5 %
 1.5 %
62%
+1%
+2%
1.0 %
+1%
+2%
1.0 %
2.
Fe% in lump ore
3.
Fe% in Sinter/ Pellet
4.
Ash% in coke
15 %
+ 1%
2%
+2%
5.
Sinter% in Burden
70 %
+ 10 %
+ 2.5 %
2.5 %
6.
BF top pressure
1.0 atg
+ 0.1 %
+1%
1.0 %
7.
Burden Distribution: PW
BLT/ TOTEM
Two Bell
Yes
+2%
- 2.0 %
8.
Si% in Hot Metal
0.5%
+1%
 (4 - 12) %
+ (5-15)%
9.
Raw Lime Stone/ Flux
+ 10 Kg
- 0.5 %
+ 3 Kg
10.
Slag rate
+ 10 kg
 0.5 %
+ 3 kg
11.
Fluctuation in Fe
1.0 % to 0.5 %
+ 2.0 %
- 2.0 %
12.
Addition of Metallic
10 Kg
+ 0.6 %
- 0.5 %
Source – Metallurgist Russian Handbook
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Internationally Benchmarked BFs
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POSCO
BF # 2
Gwangyang
Steel Works
& BF # 3
Pohang Steel
Works
BF # 1 & 5
Gwangyang
Steel Works
Design/
Operating
Parameters
Unit
Danieli
Corus
BF # 7,
Ijmuiden,
Netherlands
Useful
volume
(UV)
m3
4450
4350
4020
Working
Volume (WV)
m3
3790
3685
3445
4769
Sinter in
burden
%
42 - 50
76
74
85
85 – 86
11 - 12
Pellets in
burden
%
44 - 50
8.2
12
10
NIL
85 - 86
% (max)
6
15.8
14
14 – 15
2
-
38
38
36
% (max)
15
10-12
Iron ore
lump
In burden
No. of
tuyeres
PWIT
BF # 2,
Thyssen
Germany
44
Baoshan
Steel
BF # 1 &
2
Inland
Steel
Corp.,
USA
NDK
BF # 3,
NSC,
Kimitsu,
Japan
4063
4403
4063
3525
36
3739
38
3545
100
36
O2
enrich
ment
10
8-10
4-6
4
4-6
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Internationally Benchmarked BFs
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POSCO
Design/
Operating
Parameters
Unit
Danieli
Corus
BF # 7,
Ijmuiden,
Netherland
Production
t/d
8412 -10,632
Productivity
(on WV)
t/m3/d
BF # 2
Gwangyang
Steel Works
& BF # 3
PohangSteel
Works
BF # 1 & 5
Gwangyang
Steel Works
PWIT
BF # 2,
Thyssen
Germany
Baoshan
Steel
BF # 1 &
2
Inland
Steel
Corp.,
USA
NDK
BF # 3,
NSC,
Kimitsu,
Japan
9000
9230
11500
9025
10200
9250
2.2 – 2.8
2.37
2.68
2.41
2.17
2.5
2.5
bar
2.2
2.8
2.65
2.8-3.0
Hot blast
Temperature
0C
1250
1150 – 1200
1150 - 1200
1200
1200
1250
Coke rate
kg/thm
285 - 295
333
356
290-300
430
429
303
Coal dust
injection
kg/thm
200 - 240
200
177 – 189
200-210
75
27 (NGI)
203
Si in
Hot metal
%
0.40
0.42
0.4
0.3
Top
pressu
re
0.4
0.4
2.5
2.5
2.5
1200
0.6
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Internationally Benchmarked BFs
POSCO
Unit
Danieli
Corus
BF # 7,
Ijmuiden,
Netherland
s
BF # 2
Gwangyang
Steel Works
& BF # 3
Pohang
Steel
Works
BF # 1 & 5
Gwangyang
Steel Works
Slag rate
kg/thm
216 - 260
267
275 - 282
Coke ash
%
10.9
11
11
Charging
system
-
Bell Less
Bell Less
Bell Less
Design/
Operating
Parameters
PWIT
BF # 2,
Thyssen
Germany
285
10.5
Bell Less
Baosha
n
Steel
BF # 1 &
2
Inland
Steel
Corp.,
USA
NDK
BF # 3,
NSC,
Kimitsu,
Japan
295
290
265 - 280
11
10.6
11
Bell Less
Bell Less
Bell Less
Note: The biggest Blast furnace of more then 5000m3 with productivity around 2.5/d/m3
have also been installed in number of countries like Japan, South Korea, Russia, Germany etc.
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Indian Scenario
Indian Ironmaking has come of age with increased consciousness
amongst operators to meet the requirements of competitive iron
making at reduced cost with “Green Technologies”
The need of the hour is to adopt cutting edge innovative
technologies to achieve:
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Cost reduction
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Improve specific consumption
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Increase energy efficiency
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Improve quality, yield & productivity
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Increased automation & adopting ergonomic practices with a focus
on environmental aspect
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Present Trend in India
The present trend in India generally covers around the following
major ideas:
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Installation of bigger and large BFs to achieve economies of scale
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Facilitating high productive operation at par with global benchmark
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Increased stress on auxiliary fuel injection
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Extensive use of energy saving measures and energy heat recovery
systems
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Increased awareness for quality and consistent raw materials
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Compact installation and improved operating practices
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Extensive automation and controls
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Facilities for pollution control and environment friendly
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Long campaign life of around 20 years
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Use of top recovery turbine (TRT) for captive power generations.
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Basic Design Features of Modern Indian BFs
Some of the basic design features embedded as an integral design
concept for modern large BFs of India are:
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Design suitable for long campaign life of 15 to 20 years
High intensification levels of production > 2.0 t/ m3 WV/ day
Closed circuit cooling for efficient and contamination free cooling
High top pressure operation (1.5 – 2.5 atg)
Straight line HBT of 1200 – 1250 0 C
PCI level > 120 kg/ thm
Installation of Top Recovery Turbine (TRT) – 14 MW for 4000 m3 BF
100 % slag granulation with dewatering facilities
Advanced charging practices and high levels of Instrumentation &
automation
Maximum use of prepared burden, centre coke charging, two fraction
sinter charging, base blending etc.
Extensive use of VVVF drives
Compulsory defuming and dedusting facilities
Advance technologies for environment friendly.
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Mini Blast Furnace Sector – Indian Perspective
Even in Mini Blast Furnace (MBF) sector, plants are being built in 250
to 450 m3 size range with refractory & cooling system capable for
longer campaign life of ~ 10 years & productivity levels of more than
2.5 t/ m3/ day on working volume basis.
Some of the MBFs in this segment, such as Adhunik (Rourkela), Jindal
SAW (Bhuj), JSPL (Raigarh) & ECL (Kolkata) have touched 3.0 t/ m3/ d
productivity levels quite consistently. Some of these MBFs have
incorporated sinter charging (~ 50%) in burden & have injected ~70 kg/
thm PCI.
Top fired stoves for achieving 1200 °C hot blast temperatures are
already implemented at Sunflag & Kirloskar with good results
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Conclusions
BF productivity largely depends on:
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BF top pressure
Hot blast temperature
Auxiliary fuel injection
Burden distribution and control
BF refractory and cooling system
Quality of input raw materials
BF stock house and charging system
Automation and Control
Increase of Oxygen content in blast
While configuring the BF plant, various design & operating
parameters have to be selected in line with intensified operations
similar to international benchmarks. However, due consideration to
available raw materials & operating conditions have to be kept in
mind.
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REFERENCES
1. Metallurgists Russian Hand book. 1976
2. Modern Blast furnace – Mr. M Geerdes, H
Toxopous, C Vardesvliet
3. International Seminar on “ Iron Making in
Blast Furnaces” organized by “Steel Tech” in
September 2010 at Kolkata
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