The Different Types of Furnace Irregularities Are As Follows

THE DIFFERENT TYPES OF FURNACE IRREGULARITIES ARE AS FOLLOWS:
1. Channeling
2. Scaffolding
3. Scabs
4. Hanging
5. Slips
6. Ore shift
7. Chocking of hearth
8. Chilled hearth
9. Burning of tuyeres
10. Coke mess
CHANNELING
In a mixed bed of different sizes of materials, the resistance to gas flow increases as the
proportion of small particles or fines increases, with decrease in gas permeability and increase in
the gas pressure fall.
This causes differential gas flow in the bed, uneven gas distribution and differential gas velocities.
Where the gas velocity is more fluidization may start , smaller particles lifted up and the gas will
rush into these regions which become more and more unstable. The lifting up of the particles is
the beginning of channeling and the gas starts to show an active direct influence on the burden in
the effected areas.
Channeling can be detected by one of the following indications
1. Rise of top gas temperature

2. Sharp rise in peripheral gas temperature in and around the channel
3. High flue dust loss
4. Severe and erratic gas pressure pulsations
5. Drop in blast pressure.
Channeling can be controlled by:
1. Changing the charging sequence

2. Giving artificial slips by cutting blast pressure
3. Avoiding charging of fines since they may go to the channel and the fused mass may
strengthen the channel wall.
Scaffolding
The smooth working of the furnace may often disturbed by the formation of scaffolds that are
build ups on the furnace wall and project towards the furnace center. This interrupts the smooth
descent of the stock. The build up can occur at any place from the bosh to the upper part of the
shaft.
In general the build ups may be divided into two verities. In the low temp. regions where the liquid
do not occur, the build ups are formed in the middle and upper shaft and we name them as
scaffolds . Scabs are formed of viscous semi-fluid or liquid phase at higher temperatures in the
belly and bosh zones.
Indications of scaffolds are as follows
1. High top gas temperature

2. Low in wall temperatures at and around the scaffolds
3. Hanging, slipping and non uniform burden descent.
4. Sudden increase in flue dust generation.
Control
1. Avoidance of use of ore with large softening range.

2. Peripheral flow of gases discourage scaffolding formation
3. Avoidance of the use of fines
4. Destruction of scaffolds with explosives
5. Suitable blending of ores to reduce alkali input and softening temp. range.
Scabs
Scabs are formed in the bosh region due to changes in the physical properties of the primary
bosh slag caused by faulty burdening or irregular operation. The primary cause is sudden
lowering of the slag fusion zone, increase in slag viscosity and re solidification of the slag. as a
result an in- crustation of pasty mass forms tending to adhere to the bosh incline, a projection of
which inside the furnace obstructs the ascent of the gas and descent of the stock. If the scab is
not removed it will lead to one sided drive and damage the linings.
Scabs can be avoided by
1. Charging extra coke or melting the scab

2. Charging limestone away from the periphery to avoid formation of limy slag on the walls.
Hanging
Hanging occurs when stock meets with resistance in its downward flow or the gas in it’s upwards
flow. These can occur due to
1. Physical obstruction to burden descent due to scaffolds , scabs etc.

2. Increased gas support due to the presence of lot of fines
3. Blocking of drainage of liquid in the coke grid
4. Blocking of gas passage in the bosh due to the highly viscous slag.
Slips
Slips are sudden or rapid movement of the stock column resembling collapse. They occur due to
the formation of an initial arch or bridge inside the furnace or due to hanging in the upper part of
the furnace as a result of which the materials below continue to descend and be smelted while
the material above continue to hang. This process continues until the weight of the hanging
charge material cause collapse and sudden downwards movement. Slips lead to an increase in
temperature and pressure of the top gas as well as dust emission.
Ore shift.
The shifting of the fine ores from the region of higher permeability to those of the lower one. This
can happen because of the non uniform distribution of gas velocity arising from differential
permeability’s in different radial cross sections
Choking of hearth
Disturbance of the furnace working due to blocking of drainage of liquids through the coke grid in
to the hearth and builds ups of frozen solids on hearth walls.
Chocking may be caused by
1. Use of high melting bosh slag.

2. Excessive liquids through flow in the in the coke grid
Chocking results in irregular stock movement, delayed charging and appearance of slag in the
tuyeres quickly after tapping. Liquid iron may be entrapped in the slag and burn the tuyeres Due
to deposition of the solids in the hearth layers hearth volume decreases and the level of liquids
rises quickly after tapping.
Chilled hearth
Chilling of the hearth occurs when the hearth becomes cold and the iron temperatures fall
steeply. It can happen because of the following reasons.
1. Sudden and massive slips when cold materials fall in to the hearth
2. Collapse of relatively large materials through a large channel
3. Leaking of hearth and bosh cooling plates.
Burning of tuyeres
The burning of tuyeres can occur due to
Chocking of the bosh due to high melting bosh slags and flowing of the slag over the tuyeres and
some liquid iron entrapped within.
A peripheral flow which may chill the bottom part of the furnace, the slag becomes and the Feo
content rises, the temperature falls at the hearth periphery an the freezing of the metal occurs
between and under the tuyeres and burn the tuyeres
The remedies are
 Making a fluid, less viscous bosh and hearth slag.

 Eliminating channeling or peripheral flow.
 Continuous blowing without interruption as far as possible.
Coke mess
During casting of ion a large amount of coke comes out from the hearth along with the metal and
slag. Such a phenomenon is called coke mess and created several operating problem in the cast
house.
The coke mess may be caused by
Entrapment of small pieces of of coke in the slag rendered viscous, these coke pieces are ejected
along with the slag during casting.
The coke mess can be avoided by
1. Use of mechanically strong coke

2. Proper screening of coke and size of coke
3. Proper tap hole length
4. Uninterrupted blowing as far as possible

The Different Types of Furnace Irregularities Are As Follows

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THE DIFFERENT TYPES OF FURNACE IRREGULARITIES ARE AS FOLLOWS:

Channeling can be detected by one of the following indications

1. Rise of top gas temperature

Channeling can be controlled by:

1. Changing the charging sequence

Indications of scaffolds are as follows

1. High top gas temperature

1. Avoidance of use of ore with large softening range.

1. Charging extra coke or melting the scab

1. Physical obstruction to burden descent due to scaffolds , scabs etc.

1. Use of high melting bosh slag.

The burning of tuyeres can occur due to

The remedies are

 Making a fluid, less viscous bosh and hearth slag.

The coke mess may be caused by

The coke mess can be avoided by

1. Use of mechanically strong coke

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