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DESIGN FEATURES OFINDIAN BLAST FURNACES

Authors: 1. K R Pal Chaudhuri, GM, MECON

2. S K Verma, Jt GM, MECON3. S K Bhattacherjee, DGM, MECON

4. A Mondal, AGM, MECON

Presented by: S Sengupta, DGM, MECON

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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

• Effect of various parameters on productivity & coke rate

• International benchmarks

• The Indian scenario

Abstract

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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

BF Technology Vs Alternative Ironmaking Processes

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• TATA Steel G & H Blast Furnaces

• 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

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)

Major Recent Greenfield & Brownfield Projects of India

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Some Broad Details of Major Modern Indian BFs

Technology

SupplierClient Major Technical Data Remarks

Paul Wurth

Tata Steel, BF # H (commissioned - 2008)

Useful Volume: 3814 m3

Number of Tuyeres: 34Hearth Diameter: 13.0 mProduction: 2.5 – 2.8 Mtpa(7150 tpd for Bhushan & Tata BF #

H has crossed 10,000 tpd)Cooling System: Copper staves

SGP - PW INBA systemGCP - PW Annular Gap ScrubberTRT - 13.5 MW (design)Top charging - PW BLT systemHot blast system - PW designPCI system - PW design

Tata Steel, BF # I (under design & erection)

RINL, BF # 3(under commissioning

trials)

Bhushan Steel, BF # 2 (under construction)

POSCO e & cISP, New BF (commissioned in Nov

2014)

Useful Volume: 4161 m3

Number of Tuyeres: 38Hearth Diameter: 13.6 mProduction: 2.8 Mtpa (8000 tpd)Cooling System: Copper staves

SGP - Rasman Screw typeGCP - Bischoff Annular Gap

system TRT - 14 MW (Mitsui & Nico)Top charging- PW BLT systemHot blast system - Danieli CorusPCI system – CISRI/NMT/SPCL

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Some Broad Details of Major Modern Indian BFs

Technology Supplier

Client Major Technical Data Remarks

Paul WurthTata Steel, BF # G

(Revamped in 2005)

Useful Volume: 2648 m3 Number of Tuyeres: 30 Hearth Diameter: 11.05Production: 1.8 Mtpa (5150 tpd)Cooling System : Copper staves

Double cast housePW BLT systemPW GCP (Tangential cyclone +

two stage venturi scrubber)

Danieli Corus BVRSP, BF # 5 (commissioned in 2013)

Useful Volume: 4060 m3

Number of Tuyeres: 36Hearth Diameter: 13.2 m Production: 2.8 Mtpa (7984 tpd)Cooling System: Copper plate

coolers

SGP - DC Dewatering WheelGCP – DC Bischoff systemTRT - 14 MW (design)Top charging - PW BLT systemHot blast system - Danieli

CorusPCI system - Danieli Corus

Siemens VAI

JSW Steel (BF # 3 & 4)(BF # 3 commissioned -

2009BF # 4 under

commissioning)JSPL, Patratu (under

construction)

Useful Volume: 4019 m3

Number of Tuyeres: 36Hearth Diameter: 12.6 mProduction: Presently ~ 8000 tpd Cooling System: Copper staves

SGP - SVAI RASA systemGCP - SVAI systemTRT - 14 MW (design)Top charging - PW BLT systemHot blast system - SVAI designPCI system - SVAI design

Paul WurthBSP, BF # 8(under advanced stage

of execution)

Useful Volume: 4060 m3

Number of Tuyeres: 36Hearth Diameter: 13.4 mProduction: 2.8 Mtpa (8400 tpd)Cooling System: Copper staves

SGP - PW INBA systemGCP - PW Annular Gap

ScrubberTRT - 14 MW (design)Top charging - PW BLT systemHot blast system - PW designPCI system - PW design

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Some Broad Details of Major Modern Indian BFs

Technology Supplier

Client Major Technical Data Remarks

Paul WurthBPSL, BF #2(under advanced stage

of execution)

Useful Volume: 1701 m3

Number of Tuyeres: 24Hearth Diameter: 8.7 mProduction: 1.33 Mtpa (3800 tpd)Cooling System: Copper staves

SGP - PW INBA system GCP - PW Annular Gap ScrubberTRT - 6 MW (design)Top charging - PW BLT systemHot blast system - PW designPCI system - PW design

Paul WurthBSL, BF # 2(commissioned – 2010)

Useful Volume: 2585 m3

Number of Tuyeres: 28Hearth Diameter: 10.2 mProduction: 4500 tpdCooling System: Copper staves

SGP – Under ImplementationGCP - PW Annular Gap ScrubberTRT – Not providedTop charging - PW BLT systemHot blast system – Existing modifiedPCI system – Chinese design

Danieli CorusBV & MECON

Limited

BSP, BF # 7 (commissioned – 2007)

Useful Volume: 2355 m3

Number of Tuyeres: 24Hearth Diameter: 9.75 mProduction: 1.5 Mtpa (4430 tpd)Cooling System: Copper staves

SGP – Existing Russian systemGCP - PW Annular Gap ScrubberTRT – Not providedTop charging - PW BLT systemHot blast system – Existing Russian

designPCI system - DC design

Siemens VAIRINL, BF # 1(under commissioning)

Useful Volume: ~ 3800 m3

Number of Tuyeres: ~ 32Hearth Diameter: ~ 12.5 mProduction: ~ 2.6 Mtpa (~ 7500 tpd)Cooling System: Copper staves

SGP – Existing Russian systemGCP - SVAI Annular Gap ScrubberTRT – Existing System retainedTop charging - PW BLT systemHot blast system – Existing Russian

design (proposal for up gradation)

PCI system – Being implemented

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Some Broad Details of Major Modern Indian BFs

Technology Supplier

Client Major Technical Data Remarks

Danieli Corus BV &

MECON Limited

JSW, BF # 2(commissioned)

Useful Volume: 1681 m3

Number of Tuyeres: 20

Hearth Diameter: 8.4 m

Production: 1.25 Mtpa (3625 tpd)

Cooling System: Copper plate coolers

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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• Improved cooling system and refractory design alongwith optimum

instruments

• Proper burden distribution for proper central working, permeable

deadman and reduced heat loss

• High hot blast temperature and high top pressure BF operation

• Nitrogen lean operation i.e., oxygen enrichment upto 4 – 6 %

• Probes and instruments, particularly for controlling large BFs

• Improvement in raw material qualities w.r.t. chemistry, consistency, granulometry & ratio of prepared burden

• Provision of facilities for pollution control and environment friendly

Modern Ironmaking Practices

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Some important BF design/ operating parameters affecting plant campaign life and its productivity are:

• High BF top pressure

• High hot blast temperature

• BF top charging equipment

• BF refractory & cooling system

• Stock house configuration & charging system

• Raw material quality

• Auxiliary fuel injection

• Instrumentation & Automation

• Energy monitoring and pollution control measures

Important BF Design/ Operating Parameters

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Heat Load Fluctuation w.r.t Type of Operation & Burden Mix

Type of operation Burden mixProductivity on

Working vol.Peak heat load

KW/m2

Heat loadFluctuation

(°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% Lump2.2 – 2.7 70 – 250 50 – 105

High productivity> 30% Pellet + 50%

Sinter + Balance Lump

2.2 – 2.7 100 - 450 100 – 190

Following table provides insight on peak heat load conditions alongwith typical heat load fluctuations (oC/ min)

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 RateSl. No. Item (Parameters)

BaseValue

Change Productivity Coke Rate

1. Hot Blast Temperature

700 – 900 ° C + 100 0C + 3 % 3 %

900 – 1000 ° C + 100 0C + 2 % 2.5 %

1000 – 1100 ° C + 100 0C + 1.5 % 1.5 %

2. Fe% in lump ore 62% + 1 % + 2 % 1.0 %

3. Fe% in Sinter/ Pellet + 1 % + 2 % 1.0 %

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/ TOTEMTwo 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

Design/Operating

ParametersUnit

DanieliCorusBF # 7,

Ijmuiden,Netherlands

POSCO

PWITBF # 2,

ThyssenGermany

BaoshanSteel

BF # 1 & 2

InlandSteelCorp.,USA

NDKBF # 3,NSC,

Kimitsu,Japan

BF # 2GwangyangSteel Works

& BF # 3Pohang Steel

Works

BF # 1 & 5GwangyangSteel Works

Useful volume (UV)

m3 4450 4350 4020 4063 4403 4063

Working Volume (WV)

m3 3790 3685 3445 4769 3525 3739 3545

Sinter in burden

% 42 - 50 76 74 85 85 – 86 11 - 12 100

Pellets inburden

% 44 - 50 8.2 12 10 NIL 85 - 86

Iron ore lumpIn burden

% (max) 6 15.8 14 14 – 15 2

No. of tuyeres

- 38 38 36 44 36 38 36

O2

enrichment

% (max) 15 10-12 108-10 4-6

4 4-6

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Internationally Benchmarked BFs

Design/Operating

ParametersUnit

DanieliCorusBF # 7,

Ijmuiden,Netherland

POSCO

PWITBF # 2,

ThyssenGermany

BaoshanSteel

BF # 1 & 2

InlandSteelCorp.,USA

NDKBF # 3,NSC,

Kimitsu,Japan

BF # 2GwangyangSteel Works

& BF # 3PohangSteel

Works

BF # 1 & 5GwangyangSteel Works

Production t/d 8412 -10,632 9000 9230 11500 9025 10200 9250

Productivity(on WV)

t/m3/d 2.2 – 2.8 2.37 2.68 2.41 2.17 2.5 2.5

Top pressu

rebar 2.2 2.8 2.65 2.8-3.0 2.5 2.5 2.5

Hot blastTemperature

0C 1250 1150 – 1200 1150 - 1200 1200 1200 1250 1200

Coke rate kg/thm 285 - 295 333 356 290-300 430 429 303

Coal dustinjection

kg/thm 200 - 240 200 177 – 189 200-210 75 27 (NGI) 203

Si in Hot metal

% 0.40 0.4 0.40.42 0.4 0.3 0.6

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Internationally Benchmarked BFs

Design/Operating

ParametersUnit

DanieliCorusBF # 7,

Ijmuiden,Netherland

s

POSCO

PWITBF # 2,

ThyssenGermany

Baoshan

SteelBF # 1 &

2

InlandSteelCorp.,USA

NDKBF # 3,NSC,

Kimitsu,Japan

BF # 2GwangyangSteel Works

& BF # 3Pohang

SteelWorks

BF # 1 & 5GwangyangSteel Works

Slag rate kg/thm 216 - 260 267 275 - 282 285 295 290 265 - 280

Coke ash % 10.9 11 11 10.5 11 11 10.6

Charging system

- Bell Less Bell Less Bell Less Bell Less 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 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:

• Cost reduction

• Improve specific consumption

• Increase energy efficiency

• Improve quality, yield & productivity

• Increased automation & adopting ergonomic practices with a focus

on environmental aspect

Indian Scenario

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The present trend in India generally covers around the following major ideas:

• Installation of bigger and large BFs to achieve economies of scale

• Facilitating high productive operation at par with global benchmark

• Increased stress on auxiliary fuel injection

• Extensive use of energy saving measures and energy heat recovery

systems

• Increased awareness for quality and consistent raw materials

• Compact installation and improved operating practices

• Extensive automation and controls

• Facilities for pollution control and environment friendly

• Long campaign life of around 20 years

• Use of top recovery turbine (TRT) for captive power generations.

Present Trend in India

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Some of the basic design features embedded as an integral design concept for modern large BFs of India are:

• 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.

Basic Design Features of Modern Indian BFs

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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

Mini Blast Furnace Sector – Indian Perspective

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BF productivity largely depends on:

• 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.

Conclusions

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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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THANK YOU