Download - KNOWLEDGE ON CONTROL PARAMETERS_01
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Jayanta kr. MandalAsst. Mgr
B.F. OperationSAIL-ISP
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WHY ?
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Blast Furnace ControlThe Main Objectives :
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Furnace Control Myth
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WHAT ?Area wise details of Control Parameters
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Area wise details of Control Parameters
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Area wise details of Control Parameters
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Area wise details of Control Parameters
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Area wise details of Control Parameters
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Area wise details of Control Parameters
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Importance of some Crucial Parameters
Improved Gas Solid Contact Increased Reduction Rate Less Fluidization of Fines Less Flooding Tendency Less ‘Si’ in Hot Metal Increase in Metal & Slag Drainage Rate
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Importance of some Crucial Parameters
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Importance of some Crucial Parameters
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Importance of some Crucial Parameters
If Furnace is Operated at LOW STOCK LEVEL there will be
And these factors will eventually Increase the COKE RATE
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Importance of some Crucial Parameters
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Importance of some Crucial Parameters
RAFT
Composition of Gasses leaving this Zone
Dimension, Shape & Location
All of these Three Characteristics are controlled by BLAST & TUYERE
Parameters
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Importance of some Crucial Parameters
Kinetic energy of Blast (K.E.) = ½ . MASS. VEL2
KE of Blast effects the Depth of the Raceway(D) Zone as follows D = 0.118 X 10-3 X KE + 0.77 This in turn effects the Active Hearth Area
Positive: Raceway Depth Increases Active Hearth area Increases Per unit time Coke Burning Rate increases Productivity Increases
Negative: Coke Degradation Increases Coke Rate Increases Permeability Index decreases
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Importance of some Crucial Parameters
Parameters RAFT
H.B.T.
O2 in Blast
Steam
CDI
Natural Humidity
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Importance of some Crucial Parameters
HBT By 100oC = RAFT By 840CO2 Content By 1% = RAFT By 48-500CBlast Humidity By 1% = RAFT By 40-420c
Higher the RAFT, Higher will be the THERMAL EFFICIENY Higher RAFT will enhance the Heat Exchange between Gasses and Liquids resulting in a Higher Hot Metal Temp. Higher RAFT will lead to Lower Coke Rate & Higher Productivity
Too High RAFT may upset the Furnace Movement due to Earlier Melting of Burden Increased formation of gaseous SiO & Alkalis Flooding of slag in the coke grid due to increased tuyere gas velocity
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Importance of some Crucial Parameters
Effect of Control Parameters on H. M. Production & Coke Rate.
Change in Parameters Change in H.M. Production, %
Change in Coke Rate, %
1000C increase in H.B.T + 2.0 -3.3
0.1 atm. increase in H.T.P. +1.1 -0.5
1% decrease in Coke Ash +2.0 -2.0
1% decrease in M- 10 +2.5 -2.0
1% increase in Fe in Burden +2.0 -1.8
1% decrease in Burden Fines +1.0 -0.8
10% decrease in Not-Dry Casts +0.3 -1.0
1% decrease in Off- Rod working +0.1 -0.2
10% increase in Sinter in Burden +2.0 -4.0
1% increase in O2 Enrichment +3.0 --(no affect)
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Importance of some Crucial Parameters
Smooth Furnace Operation requires:
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Importance of some Crucial Parameters
Prior to Cast# Volume Of Metal & Slag in the Hearth , Causing –
Sharp Rise in Blast Pressure confirming the Raceway Distortion Excessive Blast & High Diff. Press. leading to the Wind Rate Reduction & Probability of Hanging
During the Cast# Due to Higher Casting/ Production Rate –
Burden Descent is rapid & irregular, Thermal requirement increases as Under prepared Burden rapidly enters the melting & Hearth Zone Stock Line Control becomes Poor
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Importance of some Crucial Parameters
Casting Parameters
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Importance of some Crucial Parameters
Casting Parameters
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Importance of some Crucial Parameters
Taphole Parameters includes: Taphole Length(L) & Taphole Diameter(d)# Hearth Drainage & Casting Rate(C.R.) depends mostly on T/H Parameters
Casting Rate(C.R.) α ------------d3
L
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Importance of some Crucial Parameters
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Importance of some Crucial Parameters
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Importance of some Crucial Parameters
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Importance of some Crucial Parameters
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Miscellaneous
RAFT = -----------------------------------------------
Where, tHB = Hot Blast Temperature, 0C
W = Oxygen in Blast,Nm3/Nm3 of dry Blast α = Blast humidity, Nm3/Nm3 of dry Blast
0.9341 tHB + 8208W – α ( 2402 – 1.2177 tHB ) + 94.76
1 + W + 2 α
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Miscellaneous Kinetic energy of Blast (K.E.) = ½ . MASS. VEL2
Mass = ------------------------------
Vel = ------------------------------------- Where, VB = Blast Rate. 10-3, Nm3/hr T = ( 273 + Blast Temp), K P = ( 1 + Blast Press.), Kg/cm2
αB = Total Humidity in Blast, g/Nm3
DT = Dia. of tuyeres, mm
n = no. of Tuyeres in operation
( 1293 + αB ).VB.0.0284 1000.n
280000.Vb.T.(18000 + 22.4 αB )
3891888.n.P.DT
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BFG
DCIV
FCVDSVGSV
Pug Mill
GRIV
BPCV
Hot Stove W-Seal
W-Seal
HE
Gas Holder
Difuser
Dust catcher
Scrubber
R.S Element Recycle Pump
MM
TBTGVIV TS
VGE
ISV
EV
BCV
MBV
M
Demister
ScrubberU-Seal
H-Tank
Drain-Pit
GRIV
TRT
M/C
COG
BGIV
TRT equipmentsTo ThickenerFrom Thickener
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Miscellaneous Top Gas Recovery Turbine (TRT) BF gas flow rate (wet) (Operation point 1) : 400,000 Nm3/h (Operation point 2) : 450,000 Nm3/h (Max flow rate) : 512,000 Nm3/h BF top pressure : 2.5 kg/cm2 gauge (max)
BF gas pressure at TRT inlet : 2.2 kg/cm2 gauge (max) : 2 kg/cm2 gauge (normal) : 1.8 kg/cm2 gauge (min) BF gas temperature at turbine inlet : 80ºC (max) : 50ºC (normal) BF gas pressure at TRT outlet : 0.125 kg/cm2 gauge (max) : 0.08 – 0.1 kg/cm2 gauge (Normal) BF gas dust content : 5.0 mg/Nm3 maximum (Dry) BF gas relative humidity : Saturated at temperature BF gas chemical composition : CO2 - 22%; CO - 25%; H2 - 4%; N2 - 49%.