Successful sale of blast furnace the valuejunction. Harbisonwalker handbook of refractory practice 2005. The paper presents the results of an investigation to determine the properties of aircooled blast furnace slag relevant to the use of the material in a road pavement base course. The 2 bucks furnace was my first use of an actual refractory formula. Any material expands when heat ed, and contracts when cooled. Consider comprehensively the factors for damaging the furnace lining according to the work environment in glass furnace such as chemical corrosion, mechanical erosion, excessive volatility and high temperature function. The age of these furnaces were more than 100 years. What is the main process of blast furnace refractory construction. Forging furnaces use an open fireplace system and most of the heat is transmitted by radiation.
Application of refractory materials for furnace refractory materials for glass furnace. Furnaces and refractories fusion dust and slag or by the action of alkalies on fireclay refractories, to form alkalialumina silicates. Refractory materials for furnace are a kind of inorganic nonmetallic materials with various excellent performances on application for industrial furnace such as glass furnace, cement kiln, ceramic kiln and coke oven. So by reducing the constituents in blast furnace gas we can increase the calorific value and can be used to generate heat and rise the temperature in any furnace. For this emergency repair there was no time to reengineer the. The iron ore concentrate is now mixed and ready for the pelletizing process. Construction of cupola furnace the cupola furnace consists of a cylindrical steel shell lined with a refractory material like firebrick and clay. Delta thermo cover range of refractory paints for protection of carbon containing refractories. A typical blast furnace may be up to 32 metres in height and 10 metres in diameter. The main refractory lining of blast furnace hearth is composed by carbon blocks that operates in.
Ashland blast furnace ho scale structure kit 9332973 thanks for purchasing this cornerstone series kit. Special monolithic refractory materials on request imported products. As with the 2dmodel, the size and shape of the 3dmodel is modelled according to a real life blast furnace. The forging furnace is used for preheating billets and ingots to attain a forge temperature. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally iron. Consequently, a balanced ratio of sic to carbon is just as important in a successful material as selecting the. A simplified diagram of a blast furnace is drawn below. Differentiated use of refractories in blastfurnace hot blast. Allied mineral products, formerly riverside refractories, offers a variety of mixes including, gunning, pumping, and shotcrete, for the blast furnace industry. Typical blast furnace internal hearth 3d geometry no refractory visible. Dependence of zinc content on particle size compared to a dustcatcher the shape of a cyclone is much thinner and smaller. With todays large blast furnaces, the main trend in hotblast stoves is toward high temperature and. Having over 80 years of experience in the iron and steel refractory product industry, our vast collection of blast furnace lining refractories are tailored to any application you may require.
How to choose refractory bricks used for different parts of. The typical campaign life of a modern blast furnace is 15 to 20 years, depending on the cooling and refractory design as a whole and the hearth area in particular. Coke is the most important raw material fed into the blast furnace in terms of its effect on blast furnace operation and hot metal quality. While blast furnace gas is plentiful, it has a low heating value, approximately 110th when compared to natural gas. A refractory material or refractory is a material that is resistant to decomposition by heat, pressure, or chemical attack, and retains strength and form at high temperatures. The business challenges the site occupied by these furnaces were needed for new projects the furnace contained multiple categories of materials. The significance of improving the refractory configuration, the installation methods, and the short turnaround time for the repair will be discussed. Refractory lining of blast furnace a modern blast furnace bf is refractory lined to protect the furnace shell from the high temperatures and abrasive materials inside the furnace.
Generally, adopt high alumina bricks, fireclay bricks and common carbon brick to build blast furnace lining, which results the short furnace life. The significance of improving the refractory configuration, the installation methods, and the short turnaround time for the. A blast furnace is a gigantic, steel stack lined with refractory brick where the concentrated iron ore, coke, and limestone are dumped from the top, and a blast of hot air is blown into the bottom. They have thick steel sides, lined with refractory bricks, to ensure that heat is not lost. Up to today, lining materials have been supplied to about 50 blast furnaces in italy and abroad always achieving excellent results and acquiring a solid reputation among the users. The refractory lining is cooled to further enhance the protection against the dispatch of excess heat that can destroy the refractory lining. Monitoring the wear of the refractory lining in the blast. Refractory walls of a furnace interior with burner. How a blast furnace works introduction the purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper. This is to certify that the thesis entitled, optimization of refractory lining used in blast furnace submitted by mr. The coke layer has a gasflow resistance smaller by a factor of 10 compared to that of the ore layer and has a high gaspermeability. Blast refers to the combustion air being forced or supplied above atmospheric pressure. Fusion cast refractories from motim magnesia chrome, sic, magnesia carbon, magnesia alumina carbon and others from wonjin.
The blast furnace body is a huge structure of 50m in height, 20m in width. The blast furnace top gas is first used to fire the hot blast stoves and the remaining blast furnace gas is exported for reheating purposes or to generate steam electrical power. The remaining refractory thickness assessment of hearth part in the blast furnace. Metallurgy and material science, fuel,furnace and refractory.
Refractory, any material that has an unusually high melting point and that maintains its structural properties at very high temperatures. The blast furnace gas can be used to generate heat. Monitoring the wear of the refractory lining in the blastfurnace hearth. The refractory bricks are produced in the great many shapes required for the correct lining of each.
R e f r a c t o r i e s f o r b l a s t f u r n a c erefractories for blast furnace 3 the chemical physical properties of the products. It should be operated not less than 15 years during one campaign. Pramod kumar bhagat in partial fulfillment of the requirements for the award of master of technology degree in mechanical engineering with specialization in thermal engineering at the national institute of. Particular tolerances, if any, should be indicated at the time of the enquiry and be the subject of tender technical. Blast furnace refractories for steel plants number of amendments. They are typically composed of oxides of the following materials. For those three parts, we should choose refractory materials with properties of thermal shock resistance, slag erosion resistance and erosion prevention. Refractories mtd 15 designator of legally binding document. In the furnace, hot metal along with slag is processed from the raw material which gets collected in the hearth and blast furnace gases come out of blast furnace from the top. When choosing refractory brick used for different lining parts of blast furnace, we should follow some principles. Application of carbon composite bricks for blast furnace hearth. Service property for refractory is the key effect on the life of blast furnace. To assess the role of each different property for a carbon.
These blast furnaces were one of the first few installed in india. It was shown that the deformation of aluminosilicate refractories depends not only upon temperature, load, and hold but also to. Best blast furnace refractory for sale in rongsheng. Copper staves were first utilised in blast furnaces in the late 1970s as the best high heatload wallcooling element.
The typical load is 5 to 6 ton with the furnace operating for 16 to 18 hours daily. Himte published on 20121129 download full article with reference data and citations. It is not intended as, and should not be taken as, a warranty of any kind, including but not limited to a warranty of. With todays large blast furnaces, the main trend in hotblast stoves is toward high temperature and pressure ventilation with dome temperature around 1550. In the service of blast furnace hot blast stoves the lining and checkerwork fail in individual zones as the result of deformation of the refractories, formation of cracks, and chemical corrosion of the lining under the action of lowmelting dust at high temperatures. However the traditional al2o3c refractory is rarely adopted in blast furnace hearth due to its low coefficient of thermal conductivity. The refractory materials and refractory bricks used in diffreent parts of blast furnace are as follows. As blast furnace productivity intensified and desired campaign life goals increased to beyond 15 years it became apparent.
The primary aim for any blast furnace is to minimize the loss in production by reducing the downtime. In the steel industry, the blast furnace is a process for making molten iron by melting iron ore. The cupola furnace is open at the both its top and bottom. Legally binding document step out from the old to the newjawaharlal nehru invent a new india using knowledge.
It does not contain recommendations for any particular refractory for any particular use. Product brochures grouting products for blast furnaces. Harbisonwalker handbook of refractory practice disclaimer. The information presented in this book is for general educational use only. The gas cleaning system contains two stages, the coarse cleaning system and the fine cleaning system. Pdf file click here for printable worksheet a simplified diagram of a blast furnace is drawn below. Blast refers to the combustion air being forced or supplied above atmospheric pressure in a blast furnace, fuel, ores, and flux are continuously supplied through the top of the furnace, while a hot blast of air sometimes with. Generally, adopt high alumina bricks, fireclay bricks and common carbon brick to build blast furnace lining, which results the short furnace life refractories used in blast furnace mainly include carbon brick, alumina silica refractory and etc. All parts are made of styrene, so use only compatible glue and paint. Cupola furnace the cupola showing the general inputs and outputs. Blast furnace refractory masonry and blast furnace refractory construction, bottomup can be divided into main processes. The furnace temperature is maintained at around 1200 to 1250 oc. Extraction of iron metallurgy blast furnace and reactions.
One of the attributing factors for higher downtime of furnace is the frequent maintenance of trough refractory working lining. Hot blast stove, apparatus for preheating air blown into a blast furnace, an important step in raising the efficiency of iron processing. This kit includes additional parts and some revisions from the original. Simple 3d geometry figure 3 shows the geometry that is used for setting up the 3d cfd model. The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and preheated air is blown into the bottom. How to choose refractory bricks used for different parts. When a larger amount of coke exists, relatively, at the center of a blast furnace, the high temperature gas, consisting mainly of co generated at the tuyeres. The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. This page will detail some of the refractory formulas that i experiment with. Jun 27, 2014 installing the refractory into the furnace body. All the three ingredients are crushed into small round pieces and mixed and put on a hopper which controls the input.
Pelletizing a pellet plant contains a series of balling drums where the iron ore concentrate is formed into soft pellets, in much the same manner that one rolls a snowball, to make a pellet about the size of a marble between 14 and 12. The refractory lining of blast furnaces and modernization of their. Longer running times and shorter downtimes for new linings or repairs mean that specific solutions are required increasingly often for the refractory lining of blast furnace stacks and runner systems. Choose the right furnace lining refractory materials and bricks for the longer. Blast furnace refractories blast furnace lining refactory. The frequent maintenance is basically the effect of high corrosion and erosion of working lining castable. Preheated air was first used by james beaumont neilson in 1828 in glasgow, but not until 1860 did the englishman edward alfred cowper invent the first successful hot blast stove. Refractory bricks used for different parts of blast furnace. Pdf wear mechanism for blast furnace hearth refractory lining.
Composed principally of ceramics, refractories are employed in great quantities in the metallurgical, glassmaking, and ceramics industries, where they are formed. Hotblast stove, apparatus for preheating air blown into a blast furnace, an important step in raising the efficiency of iron processing. Allied mineral products, formerly riverside refractories, offers a variety of mixes including, gunning, pumping, and shotcrete, for the blast furnace. When you mix this particular castable refractory, be sure to wear a dust mask. The main refractory lining of blast furnace hearth is composed by carbon blocks that operates in continuous contact with hot gases, liquid slag and hot metal, in temperatures above 1550. Learn more a blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally iron, but also others such as lead or copper. As with the 2dmodel, the size and shape of the 3dmodel is. Industry news how to choose refractory bricks used for different parts of blast furnace 20151120 how to choose refractory brick used for different parts of blast furnace.
Best blast furnace refractory for sale in rongsheng manufacturer. The charge, which consists of iron ore, coke and limestone etc. Please read the instructions and study the drawings before starting construction. Differentiated use of refractories in blastfurnace hot. Refractory materials are classified into three types based on fusion temperature melting point. A high quality coke should be able to support a smooth descent of the blast furnace burden with. With the furnace charged and the air blast on, combustion begins. Blast refers to the combustion air being forced or supplied above atmospheric pressure in a blast furnace, fuel, ores, and flux are continuously supplied through the top of the furnace, while a hot blast. Preheated air was first used by james beaumont neilson in 1828 in glasgow, but not until 1860 did the englishman edward alfred cowper invent the first successful.
What is the main construction process of refractory. The remaining refractory thickness assessment of hearth part. There are various high temperature refractory materials for refractory furnace lining application. For blast furnace whose volume is smaller than m3, we can use aluminum carbon brick. A world class blast furnace operation demands the highest quality of raw materials, operation, and operators. A comprehensive modeling and analysis of blast furnace cooling stave based on thermal stress and heat transfer analysis written by akash shrivastava, r. Refractories are inorganic, nonmetallic, porous, and heterogeneous. The refractory lining with stave 3d model in blast furnace is analyzed and design by using the. The hot blast system, incorporating either three or four hot blast stoves per blast furnace, is the other major refractory installation in the blast furnace complex. The surfaces of the refractory facing the combustion chamber of the furnace or.
They are also finding more applications in blast furnace linings, although this use is still rare. The cooling of refractory is the essential feature for the blast furnace. The three dimensional model of heat transfer of cooling stave with refractory lining in a blast furnace are. Principles for blast furnace refractory lining inspection and. All of these developments have helped result in lower iron costs, increased blast furnace campaign life and improved working conditions for operational and maintenance personnel. Blast furnace has the advantages of large output, high productivity and low cost, which is unmatched by other ironmaking methods. Traditional refractory materials for blast furnace hearth lining are mainly composed of carbon bricks and the ceramic cup. Principles for blast furnace refractory lining inspection. Provides a large variety of refractory products together with the best value which include blast furnace construction materials such as taphole brick, tuyere, linings for shaft, belly, bosh, bottom, and also consumable materials such as taphole clay, trough castable, and furthermore include refractory construction materials for hot stove. The remaining refractory thickness assessment of hearth. A comprehensive modeling and analysis of blast furnace. The principle of blast furnace operational technology and. My previous furnaces were all made from a clay form surrounded with regular concrete or mortar.
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