1050m3

&on
Technology based
350m
SHANDONG PROVINCE3
METALLURGICAL ENGINEERING
Co., Ltd.

BLAST FURNACE
Contents

1.0 Introduction
2.0 Process Flow Chart
2.1 Raw Materials and its Properties
3.0 Chemistry inside the furnace
4.0 End Product composition
5.0 Technical data
6.0 Profile dimension
7.0 Overall Process
8.0 PCI
9.0 Water Cooling system
10.0 Major unit/equipment
11.0 refractory
12.0 Specific consumption
13.0 Cranes
14.0 Utility System
15.0 Instrumentation and Automation

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 BLAST FURNACE
1.0 Introduction
1.1 The blast furnace is a metallurgical furnace lined with refractory brick, where iron ore,
coke and Fluxes are alternately charged and hot blast at 1000 to 1200°C is blown into the
furnace to chemically reduce iron oxides into liquid iron called "hot metal".
1.2 The end products are usually molten metal and slag phases tapped from the bottom, and
flue gases exiting from the top of the furnace.
1.3 There are three no’s of blast furnace in ESL namely BF#1, BF#2 and BF#3.
1.4 Electrosteel Steels Limited has 2 x 1050 m3 and 1 x 350 m3 Blast Furnaces for production
of hot metal where BF#1 is partially built.
1.5 The three end users are Steel Melting Shop (SMS), Ductile Iron Pipe (DIP) and Pig Casting
Machine (PCM)
1.6 Blast furnace consists of the following major parts
a) Stock House
b) Charging System
c)Blast Furnace
d) Cast House
e) Slag Granulation Plant (SGP)
f) Hot Blast Stoves
g) Gas Cleaning Plant (GCP)
h) Pulverized Coal Injection(PCI)
i) Water cooling system
j) PCM & LRS

2.0 Process flow of Blast furnace

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2.1 Properties of Raw Materials:

Sinter

Property Unit Requirement

Avg Fe % >=55
Basicity CaO/SiO2 >= 1.9
Tumbler Index % >= 76
RDI % Max 30
Size mm 10-40

Pellet

Property Unit Requirement

Avg Fe % >=63
Granularity mm 8-16
Compressive N/piece 2100
Strength
Tumbler index % >=91
Swelling Rate % <=14
Size mm 6-20

CLO

Property Unit Requirement

Avg Fe % >=63
Granularity mm 10-30
Size mm 10-40

Coke

Property Unit Requirement

M40 % >=80
M10 % <7.5
Coke Ash Content % <=12
Coke S Content % <=0.6
VM % <1
CSR % >65
CRI % 22-25
Size mm 25-80

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 PCI

Property Unit Requirement

Ash % < 12
VM % 10-25
S content % <0.6
Moisture % 10
HGI 50-90
Angle of repose degree <42
O
Angle of fusion C >1500
point

3 Chemistry inside the furnace

3.1 Blast furnaces operate on the principle of chemical reduction whereby carbon monoxide,
having a stronger affinity for the oxygen in iron ore than iron does, reduces the iron to its
elemental form
3.2 The blast furnaces operates as a Counter Current Exchange Process.
3.3 Carbon monoxide also reduces silica which has to be removed from the pig iron. The silica is
reacted with calcium oxide (burned limestone) and forms a slag which floats to the surface of
the molten pig iron.
3.4 The main chemical reaction producing the molten iron is:
Fe2O3 + 3CO → 2Fe + 3CO2
3.5 The preheated blast air blown into the furnace reacts with the carbon in the form of coke to
produce carbon monoxide and heat:
2 C(s) + O2(g) → 2 CO(g)
3.6 Depending on the temperature in the different parts of the furnace (warmest at the bottom)
the iron is reduced in several steps.
3.7 At the top, where the temperature usually is in the range between 200 °C and 700 °C, the
iron oxide is partially reduced to iron(II,III) oxide, Fe3O4.
3 Fe2O3(s) + CO(g) → 2 Fe3O4(s) + CO2(g)
3.8 At temperatures around 850 °C, further down in the furnace, the iron(II,III) is reduced further
to iron(II) oxide:
Fe3O4(s) + CO(g) → 3 FeO(s) + CO2(g)
3.9 As the material travels downward, the counter-current gases both preheat the feed charge
and decompose the limestone to calcium oxide and carbon dioxide:
CaCO3(s) → CaO(s) + CO2(g)
3.10 As the iron(II) oxide moves down to the area with higher temperatures, ranging up to 1200
°C degrees, it is reduced further to iron metal:
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 FeO(s) + CO(g) → Fe(s) + CO2(g)
3.11 The carbon dioxide formed in this process is re-reduced to carbon monoxide by the coke:
C(s) + CO2(g) → 2 CO(g)
3.12 The temperature-dependent equilibrium controlling the gas atmosphere in the furnace is
called the Boudouard reaction:
2CO ↔CO2 + C

3.13 The decomposition of limestone in the middle zones of the furnace proceeds according to
the following reaction:
CaCO3 → CaO + CO2
3.14 The calcium oxide formed by decomposition reacts with various acidic impurities in the iron
(notably silica), to form a fayalitic slag which is essentially calcium silicate,CaSiO3
SiO2 + CaO → CaSiO3

Figure:Different zone in blast furnace

4 End product composition

Hot metal compostion Slag Composition

Component Percentage(%) Component Percentage(%)
Carbon 3.7-4.8 CaO 34
Silicon <1.75 Al2O3 18.5
0.4-1.2 for SMS
Manganese <0.3 MgO 8.5
Sulphur(S) <0.04 CaO/SiO2 1.00
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5 Technical detail of BF#2 and BF#3

SN. Name Unit Design index

6 Profile Dimension of BF#2 and BF#3
BF#1 BF#3
SI Name Unit 3
1 BF effective volume m 1050 350
BF#2 BF#3
Number of BF Set 1 1
1 Hearth diameter mm 7600 5100
2 Production operation index of unit BF
2 Belly diameter mm 8800 5900
Productivity t/m3·d
3 Furnace throat diameter mm 6000 4000
Annual average working day d 350 350
4 Salamander height mm 1450.5
Daily pig iron output t/d 2719.5 1050
5 Hearth height mm 3800 2900
Annual pig iron output 104t/a 95.1825 36.7
6 Bosh height mm 3310 2900
7 Belly height mm 1620 1100
8 Furnace stack height mm 12570 9200
9 Throat height mm 2000 1600
10 Bosh angle 79°43′32″ 80°8′48″
11 stack angle 83°38′41″ 84°6′16″
12 Elevation of tapping hole center line mm 9710
13 Elevation of tuyere center line mm 13010
14 Total effective height of BF mm 23300 17700
15 Height and diameter ratio 2.65 3
16 Hearth area m2 45.36
17 Tuyere number Set 20 14
18 Tapping hole number Set 2 1
19 Induced angle of tapping hole and BF center 0 5
line

7 Overall Process
The following points below explains the process for BF#2.

7.1 Raw material such as coke (fuel) and sinter(IBRM-Iron bearing raw material)are conveyed
into the material transfer building(MTB) from coke oven and sinter plant respectively
7.2 Other raw materials such as calibrated lump ore,quarzite,pellet are conveyed from RMHS
through belt conveyor into the MTB.
7.3 The MTB acts as a junction to supply materials to both the stock house of blast furnace#2
and blast furnace#3

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7.4 In the MTB,a screen is arrange to disgard the fines of the raw material(coke >12mm and
sinter 5mm).The undersize sinter fines returns to sinter BF return.
7.5 The stock house recieved raw materials from the MTB and it is store in 18 bunkers to feed
the Burden (Coke, IBRM).
7.6 Raw materials from bunkers in the stock house are discharged through weigh feeders with a
screening system.
7.7 After screening,it is discharged into the weighing bin to weigh the amount of materials
consumption and is convey to a belt conveyor to discharged it to the hopper.
7.8 The hopper are equipped with electro-hydraulic bulkhead gate, which will be opened when
BF needs cokes,sinter,etc. And then the raw material can be sent to vertical environment
protection screen for screening by electric vibrating feeder.
7.9 The oversized product is unloaded in the hoisting skip car after passing though chute and
weighing system. Then it is sent to the receiving hopper of furnace top equipment with the
help of a skip car of capacity 7.5m3.
7.10 The raw materials are charge into the BLT (bell less top)with the help of a skip car.One
charging equals to 5 skips.i.e 3 skip of IRBM (32 ton) and 2 skip of coke(8ton).The charging
should be done in alternate layer.
7.11 The IRBM( iron bearing raw materials) mixed in the skip car generally consist of
Calibrated lump ore(CLO) =12%
Pellets =8%
Sinter =80%
7.12 The bell less top charging system is divided into 4 parts and it works in the below order:

UMG LSV LMG

USV
(Upper material (Lower seal (Lower material
(Upper seal valve)
valve) valve) valve)

7.13 The seals are used to prevent the leakage of BF gas.The USV is open first to avoid damage to
the seal and then the UMG is open to discharge the charging material into the burden
tank .The pressure in the burden tank is equalise to the pressure of the blast furnace i.e 140-
170 kpa so that the charging material which initially has the atmospheric pressure will be
pressurised to the blast furnace pressure with the help of an equaliser valve.
7.14 The LSV is open with the same principle that is to protect the seal valve from direct contact
with the charging material ,then the LMG gate will open to receive material from the burden
tank .
7.15 The charging materail is then discharge in the chute tilt gear box (CTGB) which can be move
in an angular manner to evenly distribute the charging materials in the furnace.

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7.16 Hot blast stove apparatus is used to preheat air blown into blast furnace which is known as
hot blast or hot air.
7.17 A main barrel supplies hot air to 20 nos. of tuyere around the furnace .The hot blast air in the
tuyere is 1180° C.
7.18 PCI pipe is also connected along with the tuyere hence there is also 20 nos. of pulverised
coal injection(PCI) pipe that is connected to the furnace to supply pulverised coal to reduce
the consumption of coke.
7.19 The tuyere is made up of 99% copper and it is connected to a cooling box to prevent it from
damaging over long term heating.the temperature in the belly is around 2200°C.
7.20 There is also 6 pumps to spray water into the BF if temperature increases beyond the limit.
7.21 The charging material are arranged in a sequence of 1 layer of IRBM over another layer of
coke to achieve proper heating and the reaction inside the furnace
7.22 Opening of the taphole is known as tapping which take place in the cast house for 2-3hrs.The
tap hole is open by a drilling machine. Based on the amount of hot metal inside the furnace
the drilling hole can be drill accordingly(40,45,50mm).
7.23 After drilling the taphole, hot metal from the furnace is discharged into the main trough(15m
x 3m) and then it flows to the skimmer for seperating slag and hot metal. The hot metal
comes out of the tap hole with atemperature of 1440-1500°C
7.24 The hot metal flows through the runner where it is discharge into the tilting runner and the
slag flow into a slag runner to sischarge it into the slag granulation plant
7.25 The main function of this tilting runner is to pour the hot metal to 2 number of the recieving
ladle i.e when the ladle is full on one side the tilting runner can be operated to tilt to the
other side of the ladle.
7.26 After the hot metal is discharge from the tap hole it is close with the help of a mud gun and
cooling of the taphole is done with the help of water pipe spray pump manually.
7.27 Slag produced is granulated and collected into SGP tank which is further lifted by grab bucket
crane and transported by mobile vehicles.
7.28 There are 4 uptake connected at the top of the furnace to allow the flow of gas out of the
furnace, these 4 uptake is connected to a downcomer where it is sent to the dust catcher.
7.29 The heavy dust particle will settle down and the clean gas with some fine travels throught
the duct to the gas cleaning plant(GCP).There are 14 barrels in GCP to collect the dust and
each barrel has 152 bag filter .These bag filter trap the dust fines and the clean gas is sent to
the BF storage tank through duct.
7.30 Incase the BF storage tank is full then a bypass valve will be open to burn the excess gas in
the flair stack with LP gas.The clean gas contains CO which will be burn with LP gas to
produce carbondioxide which can be released into the atmosphere.
7.31 The Process is repeated.The waste gas from the HBS is sent out to the chimney and to the
bypass pipe connected from the chimney pipe for supplying waste gas to the fume furnace in
the PCI plant.

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8 Pulverised coal injection(PCI) Plant

8.1 Pulverized Coal Injection (PCI) is a process that involves injecting large volumes of fine coal
particles into the raceway of a blast furnace (BF).It is use due to the following reasons

 It Reduces the need of metallurgical coke for reactions in the blast furnace
 Supplemental source of carbon.
 Speeds up the production of liquid iron.
 Use of 1 kg PCI reduces 1 kg of Coke Consumption.
 Coal Used in PCI is low VM, Low ash contained.

8.2 There are 2 PCI tanks in the plant

 PCI 1=84 TPH
 PCI 2=18.4TPH

9 Process

9.1 The type of coal used for PCI is

bituminous coal due to its carbon
percentage(72%) and HG index is
72-80%.

9.2 Coal from the dry coal shed is

transported by 2 grab bucket
crane(10MT) and dump the coal
into the 3 hopper where it is discharge into the belt conveyer which is connected to another
inclined(60 deg c) belt conveyor to transport it to the 300 TPH receiving hopper.

9.3 The hopper discharge the material into the mill grinding machine.

9.4 There are 3 static roller inside the mill 120 deg apart to the axis for grinding the coal into
fines. The roller start moving due to the movement of the plate below the roller and due to
this the material is falling centrifugally on the plate and the roller grinds it.

9.5 Due to the presence of moisture in coal, a fumes furnace is used for supplying hot air into
the mill to remove the moisture.

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9.6 BF gas, LPG and compressed air are the 3 inputs supplied to the fumes furnace for
combustion to take place upto 300°C.

9.7 For increasing the temperature, waste fumes(hot air) from the BF Stoves is used along with a
booster fan to increase the temperature upto 1000°C.Then the fumes is connected to the
mill grinder for removing the moisture and the dust is allow to flow out from the chimney.

9.8 A suction pipe is connected at the top of the mill for suction of the fines that have been
grind.the suction pipe goes into the bag filter where the fines are being trapped.

9.9 These fines is removed from the bag filter with nitrogen gas and collected in the PCI
bin.From the PCI bin it goes into the injection tank and PCI distributor.

9.10 The PCI distributor supplies PCI to blast furnace.

10 Water cooling system

10.1 To enhance the life of refractory of BF and stove valves, water cooling is provided. It consist
of water pump, valves and pipeline. Water cooling system takes place in the integrated
pump house of blast furnace and supplies for operation.

10.2 Integrated pump house 1.5 & 1.0 MPa line (BF#2)

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10.3 Integrated pump house, soft water cooling line (BF#2)

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10.4 Intergrated normal pressure water line (BF#2)
10.5 BF#3 main
pump
house
(Industrial
water) circit
of water
cooling line
(BF#3)

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11 Major unit or equipment

11.1 Stock House

The IBRM (iron bearing raw material) can be taken through G10 and G11 conveyors whereas coke
is taken through G12 conveyor belt in BF#2. The raw materials are then filled in bunkers through
heavy duty tripper car. The bunkers are equipped with electro-hydraulic gate. The raw materials
are sent for screening (cantilever vibrating type) via electric vibrating feeder.

Bunker details in BF#2 are as follows:

Bunker no Effective volume Raw Material

1 190 Pellet/ nut coke
2 190 Pellet
3 190 Dolomite
4 190 Quartzite
5 190 Sinter
6 190 Sinter
7 440 Sinter
8 440 Sinter

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 9 190 Sinter
10 190 CLO
11 190 CLO
12 190 CLO
13 190 Limestone
14 190 Quartzite
15 190 Coke
16 390 Coke
17 390 Coke
18 190 Coke
19 90 Nut coke

For BF#3 sinter is taken through K2 belt and other iron bearing material and coke can be taken
through K3 and K4 belt. Feeding can be done through ground GL1 conveyor as well. G1 to G4 or
G2 to G3 route is followed to fill raw materials in bunker.

Bunker no Effective volume Raw Material

1 270 dolomite
2 270 Sinter
3 270 Sinter
4 270 Sinter
5 270 CLO
6 270 Coke
7 270 Coke
8 270 Coke
9 292 Quartzite
10 120 Nut Coke

Skip car
The BF feeding is accomplished by lifting double skip cars along Skip
Bridge, which consists of Skip Bridge, skip car, rope sheave and hoist.
The skip car is hauled by two steel cables. The effective volume of skip
car is 7.5m3, which is of inclined type that can concentrate discharging
and reduce segregation. The two sets of rope sheaves are set up over
the skip car. The main brake of hoist is hydraulic disc brake which is of
clasp braking. The hoist is equipped with hydraulic station and
lubricating station. Maximum speed of skip car is 3.0 m/s. The skip
bridge is truss type. The wheels of skip car have mandrel structure
which prevent edge biting, deflection of skip car and rail failing phenomenon.

11.2 Bell-less top(BLT) charging system

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 The furnace top has a serial type BLT charging with top pressure of 0.17 MPa. The relief valve is
open to relieve pressure of the bunker after charging order is delivered. Then the upper sealing
valve and upper material gate is open in order to charge the burden in burden tank. After charging
process, the upper material gate, upper sealing valve close and equalizing valve is open. After the
stock rod reaches the regulated depth of stock line and lifted to the regulated level, the lower
sealing valve and lower material gate opens. The burden is distributed in furnace by distribution
chute, and the location of burden fallen into the BF is decided by adjusting the angle of α for tilting
and β for rotation of chute. The BLT adopts motor drive which is controlled by coder for α tilting
and
β angle rotation while all other equipments adopt hydraulic drive. There is a hydraulic station ,
control valve platform , grease station on furnace top platform.

Sealing valve

Sealing valve plays an important role in Bell Less Top Charging System. These valves are meant for
sealing the bin from Blast Furnace gas leakage which is driven by Hydraulic cylinder. They consist
of flap and a seat with silicon rubber seal. Flap closes against the seat during closing, once the
valve is closed, it will not allow any leakage through the valve. These valves are located one at top
of the bin and other at the bottom.

Relief valve and Equalising valve

After charging material into the blast furnace and all

the valve are closed,the BLT is ready for a new
charge.The charging material that are discharged by
the skip car into the receiving hopper of the BLT has a
atmosphere pressure i.e 1 bar,but previously the
pressure in the burden tank has been equalised to
the pressure inside the
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furnace(140kpa).Therefore the pressure in the burden tank has to be reduced to atmospheric
pressure for the raw material to fall into the burden tank,for these a relief valve is used to
decrease the excesss pressure.For equalising the pressure of the burden tank with the furnace,
an equaliser valve is operated and for decreasing the pressure of the burden tank into
atmospheric pressure for charging raw material into the the burden tank a relief valve is used.

Stock Rod
Furnace top stock rod system is equipped with 1 set of 8m mechanical stock rod, 1 set of 24m
mechanical stock rod of AC frequency conversion and 2 sets of radar stock rods. Each unit of
mechanical stock rod is equipped with a set of manual ball valve and a probe hiding box. The
lifting speed is 0.5 m/s and the falling speed is 0.25 m/s.

Distribution Chute
There are 4 distribution modes. Namely, circular distribution, helical distribution, sector
distribution and fixed point distribution. And the circular distribution includes single circle and
multi-circles. The circular distribution and helical distribution is of automatic working system,
while the sector distribution and fixed point distribution are of manual distribution .

11.3 Furnace Proper

Cooling Construction of BF
There are 15 sections of cooling staves from furnace bottom to lower part of furnace throat.

Stave No Area Type

1-5 Furnace hearth and bottom Heat resistant CI plate
6-9 Bosh, belly, lower stack Copper Stave lined with alumina carbon block
10-13 Middle and upper stack SG cast iron cooling stave
14 -15 Lower shaft SG cast iron

Hearth Lining Structure

The bottom lining of hearth consists of
the following layers:
 1st and 2nd layer- semi graphite
roasting C brick
 3rd and 4th - micro-porous C brick
 5th and 6th- plastic phase
composite corundum brick

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11.4 Tuyere Platform and Cast house
BF#2 is equipped with 20 tuyeres and 2 tap hole and BF#3 is equipped with 14 tuyeres and 1 tap
hole. Hot metal is tapped from Blast Furnace in Cast house. Tapping of hot metal is carried out
through tap-holes. Cast House is equipped with EOT crane, mud gun, drill machine, main trough,
metal runner and slag runner. Casting/tapping is carried out with the help of drill machine and the
tap hole is close with a mud gun after hot metal is tapped. Hot metal is collected in ladle and slag
is granulated in the slag granulation plant. Hot metal flows from main trough to metal runner and
then ladle via a tilting runner. Ladles are placed on both sides beneath the tilting runner

Skimmer

Apparatus for skimming slag from molten iron.

The skimmer has a small opening underneath it.
The HM flows through this skimmer opening, over
the 'iron dam, and down the 'iron runners'. Since
the slag is less dense than iron, it floats on top of
the iron, down the trough, hits the skimmer and is
diverted into the slag runners.

Drill Gun machine and Mud gun machine

The tap hole is open by a drilling machine based on the

amount of hot metal inside the furnace the drilling hole
can be drill accordingly(40,45,50mm).After drilling the
taphole hot metal from the furnace is discharged into
the main trough(15m x 3m) and then it flows to the
skimmer for seperating slag and hot matal.The hot
metal flows through the runner where it is discharge
into the tilting runner .The main function of this tilting
runner is to pour the hot metal to 2 sides of the ladle i.e when the ladle is full on one side the
tilting runner can be operated to tilt to the other side of the ladle.
After the hot metal is discharge from the tap hole it is close with the help of a mud gun and
cooling of the taphole is done with the help of water pipe spray pump manually.

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 Drill Gun machine Mud gun machine

11.5 Hot blast stove(HBS)

A hot blast stove is a facility to supply continuously the hot air blast to a blast furnace. Before the
blast air is delivered to the blast furnace tuyeres, it is preheated by passing it through
regenerative hot blast stoves that are heated primarily by combustion of the blast furnace top
gas (BF gas). In this way, some of the energy of the top gas is returned to the blast furnace in the
form of sensible heat. This additional thermal energy returned to the blast furnace as heat
reduces the requirement of blast furnace coke substantially and facilitates the injection of
auxiliary fuels such as pulverized coal as a replacement for expensive metallurgical coke. We have
3 top combustion stoves at each furnace. At a time two stoves are kept on gas i.e heated whereas
one supplies hot blast at a temperature of 1160-1180 C to the furnace.

There are 3 stages in HBS namely

1. Heating (on gas) 100 min

2. Blasting(on gas)40 min
3. Isolation

Heating (on gas):In this stage, the BF gas valve and

combustion air valve are open with the help of the
hydraulic control valve. When BF gas and combustion air
are mixed combustion take place .the checker bricks
have the capability to store the heat(1200-1300°C)
caused by combustion.
Blasting(on blast) :The valve of the cold blast supplied
from turbo blowers in power plant is open and the cold
blast passes to the checker bricks .The blast that comes out of the stoves is known as hot blast.
Hot blast flows through the bustle main in the furnace proper where it get distributed to
tuyeres.

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Isolation: The intermediate process that takes place is known as isolation

11.6 Back pressure recovery turbine (For BF#3)

For generating the blast air, blast furnaces are equipped with Axial compressors provided with
twelve stages. It is a blast furnace energy saving device which consists of blast furnace blower
system and blast furnace gas turbine power generating device. In this set of machine train, the
blast furnace blower is designed as a separate system and a HT motor with 7.2 MW power is
selected for drive the blower under max. working condition and not to affect normal productivity
of blast furnace. Blast furnace top gas pressure recovery turbine unit is an energy recovery
machine train, and its function is to transmit gas into turbine by residual pressure of blast furnace
top gas, then it expands in it. During normal operation the device could recover part of energy
required for blast furnace, replace relief valve group , control and stabilize top pressure of blast
furnace, purify gas, and make top pressure of blast furnace sensitively and the fluctuation small.
The gas of blast furnace is gradually moves through TRT when the blast furnace is in normal
operation and the variable speed clutch will automatically mesh when the TRT speed is up to the
speed of variable speed clutch, which lead to TRT, together with motor drive blast furnace. The
output power of motor is decreased and achieves the energy-saving goal.
In this set of machine train, the blast furnace blower is designed as a separate system and the
motor power is selected as per the max. power in order to separately drive the blower under any
condition under max. working condition and not to affect normal manufacture of blast furnace.

11.5.1 BPRT Consists of :

a. H.T. Motor (7.2 MW).
b. Gear Box.
c. Axial compressor.
d. Dry type gas reaction turbine.
e. Variable speed Clutch

Few auxiliary systems are:

f. Nitrogen gas (sealing and instrumentation operation)

g. Hydraulic System (operating blade angle adjusting cylinder, and different valves)
h. Lubricating System (lubrication of rotating equipments)
i. Water cooling System (cooling)

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11.5.2 Top Pressure Recovery Turbine

In order to effectively utilize the gas in downstream processes, conventionally its pressure is
reduced by the septum valve after the dust was removed. A top pressure recovery turbine utilizes
this pressure as well as temperature and recovers them as electricity by a gas turbine. As it
recently became possible to remove the dust by a dry method and increase the turbine inlet
temperature, it is expected that more electricity will be recovered.

Top-pressure recovery turbine operating on the blast-furnace top gas are designed to generate
electric power at the expense of pressure differential between the gas pressure under the blast-
furnace top and pressure in the all-factory top gas reservoir from which gas comes to the
consumer.
Further the power generated by the TRT is utilized to recover the power of the H.T. motor
needed for the running of Axial Compressor.
It has 2 stages in which the 1ST stage is the adjustable stator blade and second is the rotor blade.
Specification.
Inlet pressure 212.7kPa(A)
Inlet flow 1235m3/min
Inlet temperature 180 ℃
Turbine output power 1850 kW

11.7 Gas cleaning plant

The process of liquid iron production in the blast

furnace (BF) generates gas at the furnace top which

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is an important by-product of the BF process. This top gas is having substantial calorific value and
is known as raw BF gas or contaminated BF gas.In order to further use the raw BF gas, it is
necessary to clean it by using certain process systems which reduces its content of the solid
particles.It is used as fuel gas for heating blast air in the hot blast stoves as well as supplemental
fuel in the steel plant. For the BF gas to be used as fuel gas, it is necessary that the raw BF gas is
cleaned and cooled to reduce gas volumes and moisture content

11.8 Slag granulation pit(SGP)

The BF molten slag enters into the sluiceway from the

head of slag runner, the molten slag is impacted and
broken by the high speed water flow ejected from spray
nozzle, is cooled quickly and forms water granulated
slag. The slag after granulation falls into the sluiceway.
The outer shell of sluiceway is concrete and the lining is
anti-wearing crystal nucleus lining plate. The water
granulated slag flows into the slag pond.

A 10ton overhead bucket crane is set up over the slag pond , the slag pile is set up at one side of
slag pond using the grab bucket, which is loaded on the truck and transported to the stock yard.

11.9 Pig casting machine(PCM)

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Hot metal (HM) produced in the BF, whenever not used directly in the steel melting shop and
ductile iron pipe plant is cast into Pig iron (PI) in the PCM. The HM is solidified in the PCM to
small pieces. The Pig iron produced in PCM is in sizes generally of 10 to 45 kg/piece. Such small
sizes of Pig iron pieces are produced in PCM by pouring the HM into the mould having small
pockets. There the HM is solidified by cooling with air followed by water cooling.

PCMs are designed either for pouring HM from

open top ladles. Open top hot metal ladles are
normally tilted with the help of a tilting winch.

Two set of 61m double-chain fixed type pig

casting machine with trolley are adopted. Casting
capacity of one set is 2400t/d on condition that
the working rate is 69%. Two sets can meet the
production capacity requirement of BF

There are two sets of casting cranes with Q=50/10t，Lk=16.5m,H=13m in the iron casting room.
The lifting of main hook adopts frequency control and speed regulation to satisfy the requirement
of iron casting. The central line distance between two sets of 61m two-chain with idler roller fix
type casting machines is 36m, and the operating room is laid independently.

11.10 Ladle Repair shop (LRS)

Main function of ladle repair is to make the process of masonry, repair, and heating for the 65t
hot metal ladle, so as to satisfy the requirement by BF continuous production for hot metal ladle.

Maintenance workshop of hot metal ladle

There is one track in the workshop to satisfy the transportation requirement of old and new
ladle.65t ladle repair pit is set up in the workshop, six ladle positions are set up as well, in which
two for ladle cooling and four for masonry. There are three sets of 65t hot metal ladle baking
machine, the baking time in major overhaul is generally 16 ～36h, and the cooling time in major
overhaul is generally 4h. One set of crane with the parameter of Q=100/32T ；Lk=19m；H=13m
is selected in this design, which could meet the requirement of the maintenance ladle repair.

13. Refractory

• A blast furnace is refractory lined to protect the furnace shell from the high temperatures
and abrasive materials inside the furnace.

• The refractory lining is cooled to further enhance the protection against the dispatch of
excess heat that can destroy the refractory lining.

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 • The application condition of different regions of a blast furnace is not the same due to the
very nature of its geometry and also due to the pyrometallurgical process occurring at
different stages.

• There are diverse physical and chemical wear mechanisms in the different regions of the
blast furnace and they are complex in nature.

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13.1 Refractories used in different units of BF

Area Present Trend

Stack 39 % – 42 % Al2O3 Super duty fireclay
Belly 39 % – 42 % Al2O3 Corundum, SiC-Si3N4
Bosh 62 % Al2O3, Mullite SiC-Si3N4
Tuyere 62 % Al2O3, Mullite SiC self bonded, Alumina-
chrome (Corundum)
Lower hearth 42 %-62 % Al2O3, Mullite, Carbon/Graphite block with
Conventional carbon block super micro pores
Tap hole Fireclay tar bonded, High alumina / Fireclay tar bonded, High
SiC tar bonded alumina / SiC tar bonded
Main trough Pitch / water bonded clay / Tar Ultra low cement castables
bonded ramming masses, Castables (ULCC), SiC / Alumina mixes,
Gunning repairing technique
Tilting spout High alumina / SiC ramming High alumina / SiC / Carbon /
masses / Low cement castables ULCC

14. Ideal Specific Consumptions

14.1 Raw Materials

Assuming Furnace is being charged sinter: 80%; Iron Ore: 10%; Pellet : 10%

And Sinter Fe - 57 % and burden Fe-58.2%

Raw Materials UOM Specific Consumption

(net & dry)
Sinter kg/tHM 1320
Iron Ore kg/tHM 165
Pellet kg/tHM 165
Net IBRM kg/tHM 1650
Quartzite kg/tHM 25
Coke kg/tHM 330
Nut Coke kg/tHM 40
PCI kg/tHM 170
Net Fuel Rate kg/tHM 540

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14.2 Utility

Utility UOM Specific Consumption

Electricity (BF2/BF3) Kwh/MT 60/110
Nitrogen Nm3/MT 60
Oxygen M3/MT 73
Steam MT/MT 0.360
Water Nm3/MT 0.360
Compressed Air Nm3/MT 50
BF gas Nm3/MT 850
LPG Kg/MT 0.26

15. List of Cranes

SL. NAME OF THE SAFE WORK

LOCATION
NO. EQUIPMENT LOAD (SWL)

16/3.2 T X 22.5 M span

1 Cast House (BF#3) 16/3.2 T
DG EOT crane, A6, M6

16 T X 2.2 M span BLT Furnace Top

2 16 T
trolley, A5, M5 (BF#3)

5 T X 7.5 M span SG U/S Water Pump House

3 5T
EOT crane, A5, M5 (BF#3)

32/5 T X 15.6 M span Blower House (BPRT),

4 32/5 T
DG EOT crane, A5, M5 BF#3

10 T X 5 M span SG EOT
5 Hot Blast Stove (BF#3) 10 T
crane, A5, M5
20 T X 31.5 M span DG East Cast House
6 20 T
EOT crane, A6, M6 (BF#2)
20 T X 31.5 M span DG West Cast House
7 20 T
EOT crane, A6, M6 (BF#2)
10 T X 31.5 M span DG Slag Treatment (SGP)
8 10 T
EOT with Grab, A6, M6 Pump house side
10 T X 31.5 M span DG Slag Treatment (SGP)
9 10 T
EOT with Grab, A6, M6 Middle
10 T X 31.5 M span DG Slag Treatment (SGP)
10 10 T
EOT with Grab, A6, M6 Control room side

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 10 T X 9 M span SG EOT,
11 SGP Pump House 10 T
A5, M5
EOT Crane SG Hatch Cover Platform
12 10 T
Span - 5 Mtr. (BF#2)

13 EOT Crane DG BLT Top (BF#2) 25 T

EOT Crane DG Hot Blast Stove 26 M.

14 15 T
Span - 10 Mtr. (BF#2)
EOT Crane SG Integrated Pump
15 5T
Span - 8 Mtr. House (BF#2)
EOT Crane SG Integrated Pump
16 5T
Span - 8 Mtr. House (BF#2)
10 T X 31.5 M span DG Coal Storage Area
17 10 T
EOT with Grab, A6, M6 (PCI), Sinter Plant Side

10 T X 31.5 M span DG Coal Storage Area

18 10 T
EOT with Grab, A6, M6 (PCI), Lime Plant Side
50/10 T X 16.5M Span
19 DG EOT A7, M7/M6 PCM-1 Casting Crane 50/10 T
Make: Weihua
50/10 T X 16.5M Span
20 DG EOT A7, M7/M6 PCM-2 Casting Crane 50/10 T
Make: Weihua
16 T X 33.5 M span DG
PCM (Pig Storage
21 EOT with magnet, A6, 16 T
Yard)
M6
12.5 T X 33.5 M span
PCM (Pig Storage
22 DG EOT with magnet, 12.5 T
Yard)
A6, M6
3 T, 18 M lift electric
PCM (Settlement
23 single rail wrap crane 3T
Pond)
with Grab, A5, M5
100/32T X 19M span Laddle Repair Shop
24 100/32 T
EOT crane (LRS)

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