Plus the burden descent and ascending gas flow of scour and wear. When you mix this particular castable refractory, be sure to wear a dust mask. Tailormade solutions for reheating furnaces in the steel. These materials consist of a refractory hydraulicsetting cement phase, typically compounds of calcium oxide and aluminum oxide called calcium aluminates, and an aggregate material. 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.
A hot blast stove is a facility to supply hot air to a blast furnace continuously. It mainly needs to withstand impact and abrasion of burden, so generally we use steel brick or water cooling steel brick for the furnace throat. 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. Refractory, any material that has an unusually high melting point and that maintains its structural properties at very high temperatures. 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. Calculation of blast furnace size is empirical in nature.
The main refractory lining of blast furnace hearth is composed by carbon blocks that operates in. In the steel industry, the blast furnace is a process for making molten iron by melting iron ore. The three dimensional transient navierstocks equation associated with the volume of fluid vof was developed to describe the flow fields of air, molten iron and slag in the main trough of the blast furnace during tapping process. In the combustion heat accumulation phase, heat energy in hot exhaust gas from a burner is accumulated in checker bricks and, in the ventilation phase, a large quantity of air is blown through the checker bricks to raise the temperature of the air. Jun 27, 2014 installing the refractory into the furnace body. Choosing the best refractory material for an aluminum furnace. Optimization of refractory lining used in blast furnace a thesis submitted in partial fulfillment of the requirements for the award of the degree of master of technology in mechanical engineering thermal engineering by pramod kumar bhagat 2me3425 department of mechanical engineering national institute of technology rourkela odisha769008, india. Blast furnace, bottom and hearth, refractory, salamander, blowin introduction this paper relates to the blowin of csns blast furnace number 3 in 2006. Nippon steel began to use carbon blocks as the refractory for blast furnace hearths in 1951. Optimization of refractory lining used in blast furnace a thesis submitted in partial fulfillment of the requirements for the award of the degree of master of technology in mechanical. Replacing firebrick by highalumina brick and even dinas does not completely solve the problem of the low resistance of the linings in the hot. Industrial materials called castable refractory concrete are widely used for furnace linings and multipleuse mold materials in metallurgical and ceramic industries. Composed principally of ceramics, refractories are employed in great quantities in the metallurgical, glassmaking, and ceramics industries, where they are formed into a variety of shapes to line the interiors of furnaces, kilns, and other devices that process.
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. Allied mineral products, formerly riverside refractories, offers a variety of mixes including, gunning, pumping, and shotcrete, for the blast furnace industry. Nov 05, 2014 home office 1907 vanderhorn drive memphis, tn. Principles for blast furnace refractory lining inspection.
Armil cfs ceramic fiber boards offer low thermal conductivity, high temperature stability, uniform density, and excellent resistance to chemical attack. The excellent rigidity and modulus of rupture for these boards makes them strong and selfsupporting, yet lightweight and easy to cut or fabricate. The same method can be used to tell if cracks in refractory materials are closing properly when the furnace is fired. Precast shapes are manufactured using high quality castable mixes. Furnace wall design furnace is a confined space in which fuel is burnt to liberate heat energy. The blast furnace body is a huge structure of 50m in height, 20m in width.
The samples were then soaked at 1200oc for 8 hours and allowed to cool in the furnace for 24 hours. If the cracks are dark, showing that they do not close, they should be repaired. Performance evaluation of refractory bricks produced from. Measurement of blast furnace refractory lining thickness with a 3d laser scanning device and image registration method article pdf available in isij international 4810.
During the operation of a blast furnace cyanides form in the furnace gases which during shortterm stoppages get into the hot blast tract and the stoves, and tend to destroy the refractory materials. Blast furnace is the focus of any integrated steel plant. Numericalexperimental analysis of thermal shock damage in. Carbon and graphite refractories are primarily used for blast furnace linings because of their high temperature conductivity and their ability to reduce the heat load by moving the excessive heat to the shell where the heat can be transferred to the water by film cooling or through the cast iron or copper staves. Brick installation guide pdf smithsharpe fire brick supply. Numerical simulation was conducted to simulate the heat transfer and flow in. Part of the gas cleaning system of a blast furnace in monclova, mexico. Best blast furnace refractory for sale in rongsheng. Legally binding document step out from the old to the newjawaharlal nehru invent a new india using knowledge. Here are some methods of selecting refractory brick for every part of furnace lining. Failure analysis of bullnose refractory in reheating furnace. Refractory wear rate is evaluated by considering the fluid flow speed at the refractory walls. The remaining refractory thickness assessment of hearth part in the blast furnace. The significance of improving the refractory configuration, the installation methods, and the short turnaround time for the repair will be discussed.
In the past, the occurrence of thermal shock in refractory materials has. The refractory acts as both an insulating material and a protective layer for preventing the external walls of the boiler from getting damage. Ceramic fiber boards for high temp furnaces armil cfs. Air heated in the blast furnace stoves, is applied from the bottom of the furnace. They provide efficiency, security of operation and reliability for the following applications and units. Armil cfs bricklayers and insulation installers are skilled at installing insulating firebrick, firebrick, ceramic fiber, and cast refractory linings. Blast furnace refractories for steel plants number of amendments. Blast furnaces are lined by carbon and graphite refractory bricks to protect the integrity of the vessel. The structure of the furnace consists mainly of refractory bricks and cement. Limestone is used to remove impurities such as slag.
Refractories are mostly dictated by application parameters such as thermal process temperature profile and atmosphere. Simple 3d geometry figure 3 shows the geometry that is used for setting up the 3d cfd model. A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. Measurement of blast furnace refractory lining thickness with a 3d laser scanning device and image registration method. Namho shin, sangwoo choi, yongrae roh, posco, pohang, korea. Pdf the developments of a blast furnace lining and cooling concept are discussed.
One of the attributing factors for higher downtime of furnace is the frequent maintenance of trough refractory working lining. Pdf measurement of blast furnace refractory lining. Blast furnace stack the refractory material is subjected to attack from co atmosphere, alkalines, and mechanical wear. During the first lining of the blast furnace 2, the refractory brickwork was renewed and all. Choose the right furnace lining refractory materials and bricks for the longer. Application of refractory materials for furnace refractory materials for glass furnace. There are various high temperature refractory materials for refractory furnace lining application. Refractory relines armil cfs personnel supply, install and repair refractory and insulation in high temperature furnaces, kilns, incinerators, and ovens. Principles for blast furnace refractory lining inspection and. Energy saving in walking beam furnaces by a new concept for skid pipe insulation by jens heinlein, heiko siefkes, michael springer, frank hugel, andreas buhr, rainer kockegeylorenz increasing energy costs and targets for the reduction of co 2 emissions provide a constant challenge for all high tempera. C, blast temperatures of 1250 1400 c, and furnace pressures of 3 5 kgcm2.
Blast furnace refractories blast furnace lining refactory. This section introduces furnaces and refractories and explains the various design and operation aspects. Extraction of iron metallurgy blast furnace and reactions. This property is important when the refractory is in contact with molten charge and slag. For a blast furnace, the hearth erosion profile is mainly determined by the temperature distribution in the refractory. It should be operated not less than 15 years during one campaign. The cooling apparatus is usually comprised of slag skull, refractory lining, cooling stave, and filling materials at interfaces and furnace shell. Allied mineral products, formerly riverside refractories, offers a variety of mixes including, gunning, pumping, and shotcrete, for the blast furnace.
Iron making solutions to extend blast furnace lifetime. Refractory materials are used in furnaces, kilns, incinerators, and reactors. The type of material used in the the furnace walls of the boilers is known as refractory material. Refractory materials for industrial furnaces onex, inc. High temperature depending on furnace operational requirements.
This study aims to numerically analyze the refractory wear of the blast furnace main trough. Typical blast furnace internal hearth 3d geometry no refractory visible. Numerical analysis on the refractory wear of the blast. For good corrosion resistance and easy formation of a protective. See figure for the latest design installed at corus ijmuiden blast furnace no. Our procurement department can help you decrease inventory costs, eliminate waste and save time. For this emergency repair there was no time to reengineer the.
Energy saving in walking beam furnaces by a new concept. Blast furnace cooling stave and refractory lining dimensions of blast furnace cooling components and materials type are shown in table 1 and table 2 respectively. Differentiated use of refractories in blastfurnace hot. 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 apparent porosity is the volume of the open pores, into which a liquid can penetrate, as a percentage of the total volume of the refractory. Energy saving in walking beam furnaces by a new concept for.
The remaining refractory thickness assessment of hearth. Monitoring and control of hearth refractory wear to improve blast furnace operation. Differentiated use of refractories in blastfurnace hot blast. It was shown that the deformation of aluminosilicate refractories depends not only upon temperature, load, and hold but also to. 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. With todays large blast furnaces, the main trend in hotblast stoves is toward high temperature and pressure ventilation with dome temperature around 1550.
The iron ore concentrate is now mixed and ready for the pelletizing process. Consequently, a balanced ratio of sic to carbon is just as important in a successful material as selecting the. Particularly in the steel industry there exists a demand for a highperformance continuous production process. Blast furnace is used to reduce the iron ore to iron. Service property for refractory is the key effect on the life of blast furnace. The approach adopted to analyse the root cause for the failure of bullnose refractory was the rigorous analysis of the failed refractory which was collected during the major shutdown of the reheating furnace of hot strip mill at tata steel. The structural problems of this blast furnace are cracks of the steel shell and thickness reductions of the stave and the refractory of hearth part caused by. Pdf wear mechanism for blast furnace hearth refractory lining. The charge, which consists of iron ore, coke and limestone etc. Firebrick and ceramic fibers are the most common used refractory materials for high temperature furnaces and kilns. This stands in contrast to the cup test, in which a crucible of the refractory, or a cavity drilled into a brick of the material, is filled with slag and heated in a furnace. 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.
The primary aim for any blast furnace is to minimize the loss in production by reducing the downtime. Pdf monitoring and control of hearth refractory wear to. Blast furnace products and there use size of blast furnace design of blast furnace is evolved through experience. Pdf wear mechanism for blast furnace hearth refractory. The three dimensional model of heat transfer of cooling stave with refractory lining in a blast furnace are. Refractory relines for high temp kilns and furnaces. Refractories for reheating and heat treatment furnaces.
Aim of furnace design is to make an arrangement for maximum heat release from the fuel within the combustion chamber and arrangement of sufficient heat absorbing surfaces so as to abstract the liberated heat to the fullest extent. Jet refractory, regardless of the spraying repatching or build new lining body, accept the spray on the working plane jet material status can be divided into. Since the first firing of a plastic or castable burner front does more damage than any other single firing, the first inspection after installation. Refractory systems iron and steel industry steulerkch. The refractory lining of every part should fit the parts thermal current intensity, so that the lining can maintain previous vertebral shape and stability under the impact of strong heat flux. Refractories mtd 15 designator of legally binding document. Torpedo ladles must ensure safe transport of the pig iron from the blast furnace to the steelworks. Furnace technologies supplies a range of refractory materials for repairing or building furnaces and kilns. Type of furnaces and refractories high emissivity coatings emissivity. Mode of waste heat recovery recuperative regenerative unep 2006 15 type of furnaces and refractories used to preheat billetsingots use open fireplace system with radiation heat transmission temp 12001250 oc operating cycle heatup time soaking time forging time fuel use. The hotface is at the refractoryslag interface and temperature drops across the refractory. Expansion phenomena in blast furnace hearths after blowin. At onex, we offer a wide range of products in refractory materials that range from castables, ceramic fiber products, firebrick and insulating brick, mortars, and plastic refractories. The lining should be capped with a layer of good refractory cement of equal thickness so that the furnace cover rests evenly and a good seal is provided.
Publishers pdf, also known as version of record includes final page, issue 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. Carbolite furnace at intervals of 100oc for every 10 minutes till the temperature of 1200oc was reached. Precast refractory shapes are pre fired and can be put right into service in your high temperature application. Failure analysis of bullnose refractory in reheating. Why refractory materials are required in boiler furnace. A methodology to investigate the wear of blast furnace hearth. Insulating, abrasion resistant, low cement, no cement, and conventional mixes are available.
Differentiated use of refractories in blast furnace linings. 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. All the three ingredients are crushed into small round pieces and mixed and put on a hopper which controls the input. Pre cast refractory shapes for high temp furnaces and kilns.
A refractory material or refractory is a material that is resistant to decomposition by heat. Now there are nearly 700 blast furnace available in world. The frequent maintenance is basically the effect of high corrosion and erosion of working lining castable. It is therefore evident the absolute necessity to carry into effect a severe policy of quality in manufacturing.
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. 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 refractory bricks are produced in the great many shapes required for the correct lining of each. It is therefore evident the absolute necessity to carry into effect a severe policy of quality in.
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