Enhanced blast furnace operation and service life by improved monitoring and control of the hearth and uniformity
The competitiveness and productivity of the iron-making industry relies significantly on the operational lifetime of the blast furnace. Specific attention has to be paid to the hearth, since its refractory wear is often decisive for campaign length. Wear and skulling of the hearth are closely related to internal hearth and dead man conditions, which are known to play an extremely important role for iron and slag flow, hot metal composition and temperature. Non-uniform operation can lead to excessive wear and, as a result, expensive repairs - even if other areas of the blast furnace may still be in good condition. A more uniform operation improves hot metal quality, lowers the fuel rate and increases hearth and stave life. The wear profile of different blast furnaces across Europe was documented and samples of refractory were analysed. Based on these results, hearth supervision was improved to monitor refractory decay which up to now cannot be detected. Several campaigns of tap hole pressure measurement were carried out. Average void fractions of the dead man were determined and correlation with EMF was found. A new tapping management system, based on CCD-cameras and a suitable software platform was tested. Internal hearth conditions were investigated with hearth supervision systems, CFD-simulation, tuyere drillings and additional measurement data. An acoustic measurement technique to indicate charging irregularities and combustion problems was successfully tested. Subsequent countermeasures improve blast furnace uniformity. The results described increase blast furnace life, stability and security. Given that higher productivity and lower fuel consumption can be expected, this research clearly contributes to the sustainable development of the European Steel Industry.
Bibliographic Reference: EUR 23455 EN (2008), 125 pp. Euro: 20
Availability: http://bookshop.europa.eu/is-bin/INTERSHOP.enfinity/WFS/EU-Bookshop-Site/en_GB/-/EUR/ViewPublication-Start?PublicationKey=KINA23455 (Catalogue Number: KI-NA-23455-EN-S)
ISBN: ISBN: 978-92-79-08775-2
Record Number: 200910528 / Last updated on: 2009-12-21
Original language: en
Available languages: en