A Presentation on

Furnace Proper
FURNACE PROPER

Presented by
Sanjay verma
D P Chandra
PRESENTED BY
GOPAL KUMAR
Chandra Shekhar Verma
General Design Parameters

General Unit Data

Hot Metal Production Thm /24h Avg : 9500
(delay free) Design: 9900
Availability Day/Y Min : 350
Useful Volume m3 4506
Working Volume m3 3815
Number of tuyer - 38
Hearth Diameter m 14.2
Throat Diameter m 10.8
Tap Holes Nos. 4
Cast House Twin (East & West side)
Cooling System Stave & Plate
Burden and Fuel Injection
Coke Rate, Kg/ thm Design : 360 (with 150kg/thm PCI)
(Incl. Nut Coke) 525 (all coke)

Nut Coke Kg/ thm Design : 30

Coal Injection Kg /thm Norm : 150
Max : 200
Total Fuel Rate Kg/ thm Design : 510 (with 150kg/thm PCI)
: 525(all Coke)
Iron Burden - Sinter : 80%
Lump Ore : 20%
Pellets : 0 to 20% (future)
HOT BLAST

Blast Volume Nm3/min (dry) Norm : 6300@1250.C

Nm3/min (wet) Design : 7140@1250.C
Oxygen % Max :6
Enrichment Design : 6
Temperature C
o
Max : 1250
Design : 1250
Moisture g/Nm3 Norm : 45
Design : 50
Pressure Kg/cm2(g) Max (operating) : 5.0kg/cm2
Design : 5.5
 Top Gas
Top Gas Volume Nm3/hrs Max : 653000
(dry) Design : 679000

Top Pressure Kg/cm2(g) Max (operating) : 3.0

Designed : 3.5
Temperature C
o
Min : 100 oC
(operating) Avg : 150 oC
Temperature for C
o
Norm : 180-200
Top Charging
Equipment
Standard Gas %dry Design: CO : 27.4, CO2 : 21.1
Composition H2 : 6.3
Hot Metal
Temperature C
o
Min : 1450, Max : 1500
SLAG
Slag Rate Kg/thm Design : 269
Temperature Min : 1530,Design : 1570
Individual batch weights (Normal 150 kg PCI )
Material Amount (Ton)

Lump ore 22.0

Total sinter: 87.8
• Small sinter 4.3
• Sinter 83.5
Nut Coke 2.1
Total Coke: 22.8
• Surface Coke 17.1
• Center Coke 5.7

Total ore batch 112.0

Total coke batch 22.8

TOP
Number of rings Ore : 12
Number of rings Coke : 14
Ore layer thickness : 70cm
Coke layer thickness : 50cm

Discharge Times (Ore) : 100 Sec

Discharge Times (Coke) : 90 Sec
 TOP INPUTS: FURNACE
 COKE
 SINTER
 LUMP ORE
 DOLOMITE
 LIMESTONE
4984 M³ Throat 10.8 m Throat Amours
450°C
3815 M³ TOP OUTPUTS:
 BF GAS- CO,
4506 M³ W CO2, N2,H2)
600° C
O  DUST
R
U K Stack
S I
E N
F G 900° C
U
L v
O
V L
TUYERE INPUTS O U
L Belly
 WIND (O2 & N2) M
 PURE OXYGEN U E
 MOISTURE M Bosh 15.160 m
 FUEL INJECTION E ~2200OC
 (COAL) Tuyeres 38 nos.
TAPHOLES OUTPUTS:
10° Hearth - 14.2 m  LIQUID IRON
Bog depth  LIQUID SLAG
~1500OC Tap hole
3370 MM Tadpole Jacket
Hearth Bottom
BLT TOP EQUIPMENTS
 BLEEDER VALVES
 MAIN CHARGING CONVEYOR
 ROCKER
 HOPPERS
 UPPER SEAL VALVES
 MATERIAL FLOW CONTROL GATE
 LOWER SEAL VALVES
 EQUALISING VALVE (Primary & Secondary )
 RELIEF VALVES
 RELIEF SILENCERS
 DISCHARGE FUNNEL
 EXPANSION BELOW
 GOGGLE VALVE
 PLANETORY GEAR BOX
 DISTRIBUTION CHUTE
BLEEDER VALVE Nitrogen at Bleeder
platform is used to
purge/flush the
D(Semi Clean) seating gap of the
Bleeder valve.

A(North )

B(Centre)

C(South)

Elevation : 100mtr
 BLEEDER VALVE Details

System SEMI CLEAN NORTH CENTRE SOUTH

GAS (D) (A) (B) (C)
Hydraulic working 160-180 BAR 160-180 BAR 160-180 BAR 160-180 BAR
pressure
Diameter 630MM 630MM 630MM 630MM
Operation pressure 2.85 kg/cm2 2.90 kg/cm2 2.95 kg/cm2 3.00 kg/cm2
Spring setting 3.30 kg/cm2 3.30 kg/cm2 3.30 kg/cm2 3.30 kg/cm2

All Bleeder Opening Time : 4 Seconds

& Closing Time : 3 Seconds

Main charging Conveyor (MCC-01)

Length : 423 mtr.

Width : 2000mm

Speed : 2.0m/sec

Material Presence Detector: 03

Belt Rupture Sensing Device: 01

Belt Weigh Scale: 01

Distribution Rocker

.
MAXIMUM TILTING ANGLE : 500
NORMAL TILTING ANGLE : 450

{HYDRAULICALLY OPERATED}

HYDRAULIC PRESSURE : 180 bar

NEUTRAL POSITION TO HOPPER 1 : 3 Sec.

TILT TO BACK NEUTRAL : 3 Sec.
NEUTRAL POSITION TO HOPPER 2 : 3 Sec.
TILT TO BACK NEUTRAL :3
Sec
HOPPER
DESIGN DATA
VOLUME -80m3(each)
LOAD CELL-3 nos

Volume
Ore Batch : 64m3
Coke Batch : 46m3

HOPPER 1 HOPPER 2
LEVEL SWITCH AND LOAD CELL
UPPER SEAL VALVE

 Operation hydraulic pressure : 180-200 kg/ cm2

 Upper seal valve opening time : 3 Sec.
 closing time : 3 Sec.
 Dia : ND 1100mm
 Valve Heating : Steam
 MATERIAL FLOW CONTROL GATE

Operation hydraulic pressure 180-200 kg/ cm2

Material Flow Control Gate opening time 6 Sec.
closing time 4 Sec.
Maximum Opening Speed 150/Sec.
Low Opening Speed 50/Sec.

ANGLE 0 Degree to 75 Degree.

 LOWER SEAL VALVE

Operation hydraulic pressure : 180-200 kg/ cm2

Lower seal valve opening time : 3 Sec.
closing time : 3 Sec.
Dia : ND 1100mm.
EQUALIZING VALVE Primary
Equalizin
g

Relie
f

Secondary Equalizing

EQUALIZING 2 Nos.
Supply – Nitrogen
HYDRAULIC PRESSURE 180-200 BAR
Supply pressure – 18 kg/cm2
VALVE DIA 500 MM Dia - 250 mm
OPENING TIME 3 Sec.
CLOSING TIME 3 Sec.
Equalizing Time 40 Sec
 RELIEF VALVE

RELIEF
VALVE

RELIEF VALVE 2 Nos.

HYDRAULIC 180-200 BAR

GOOGLE PRESSURE
VALVE VALVE DIA 500 MM
OPENING TIME 3 Sec.
CLOSING TIME 3 Sec.
RELIEF Time 30 Sec
RELIEF
Elevation : 80mtr
SILENCERS

PURPOSE IS TO
REDUCE THE SOUND
DURING HOPPER
DEPRESSURISING
Arrangement above Planetary gear box

SONIC SENSOR

DISCHARGE FUNNEL
EXPANSION BELOW

Shock wave Detection produced by

material impact on casing wall
GOGGLE VALVE

Google valve
Open to furnace time: 12 Sec.
Close to furnace time : 12 Sec.
Clamp time : 2 Sec
Unclamp time : 2 Sec

Goggle Valve at above Planetary Gear

Box is used for the isolation of the
Furnace from the Bell Less Top in order to
carry out any maintenance work during
shutdown.
Planetory Gear Box

1 Water Cooled Type , 2 Cooling System of the Gear Box

a. Water :
Water Quality : Soft Water
Maximum flow rate : 25m3/hr
Inlet pressure : 3 bar
maximum outlet Temp (Gear Box) : 550c
b. Nitrogen :
Nitrogen for purging & Cooling purpose
Nitrogen Flow : approx. 300 Nm3/h
Inlet pressure : 3 bar
 Distribution Chute

Motor For CHUTE

ROTATION

CHUTE
TILTING

1 Distributor Chute length : 4.7 m

2 Chute rotation : 8 rpm
3 Chute tilting : 1.60/ Sec
4 Concentric Position : 11
5 Normal Top Temp. : 150-2000c

6 20 to 530 for Normal Operation & 00 to 800 for Maintenance

 ON FURNACE EQUIPMENTS
Nos.
 RADAR STOCKLINE RECORDER 2
 STOCK LINE INDICATORS 2
 ABOVE BURDEN PROBES 4
 SHORT IN-BURDEN PROTECTION TUBE 4
 SHORT IN-BURDEN PROBE 4
 THERMAL IMAGE CAMERA 1
 IMPACT BURDEN PROBE 1
 RADAR PROFILE METER 11
 REFRACTORY WEAR ROD 28
 BURDEN SPRAY WATER 8
 NITROGEN INJECTION 3
 STEAM INJECTION 3
 CAST IRON STAVES 52*5+4+40*4=424
 COPPER PLATE 38+38+76+76+40*52=2308
 TUYERE 38
 BOTTOM PLATE THERMOCOUPLE 4
 HEARTH BOTTOM THERMOCOUPLE 24
 HEARTH WALL THERMOCOUPLE 28
ABOVE BURDEN PROBE (4) Elevation :42 mtr

720

1620

3420
2520

6 5 4 3 2 1
Temperature (6Points )
Gas Analysis (6Points ) CO, Co2 & H2
 ABOVE BURDEN PROBE
Length of above burden probe : 6040mm
No. of thermocouple in one burden : 6
Operational Condition

Normal : 150-200 Degree Celsius

Max : 250 Degree Celsius
Cooling System : Nitrogen Cooled
Flow : 350 Nm3/hr
Nom pressure: 3 kg/cm2
Max pressure : 4 kg/cm2
Design pressure : 8 kg/cm2
SHORT IN-BURDEN PROCTECTION TUBE 4
Elevation : 38mtr
SHORT IN-BURDEN PROBE 4
1030

130
1930

2830

Length :(1800 mm)

Temperature (3 Point) & Gas Analysis (1Point)

THERMAL IMAGE CAMERA
Elevation : 44mtr (1 Nos.)

Designed for continuous visual observation

of whole blast furnace top interior.
Includes the BF Top gas flow & burden
Distribution monitoring.
STOCKLINE INDICATORS
Elevation : 44mtr

RADAR STOCKLINE
MECHANICAL STOCK LINE INDICATORS(2NOS)
RECORDER(2NOS)
 BURDEN IGNITION / DRAFT HOLE

Elevation : 42mtr (4 Nos.) During shutdown, in order to

ignite the CO at top, Firing is
Elevation : 38mtr (4 Nos.) done through these Draft Holes.
RADAR PROFILE METER

A set of 11 no's of Radars will show the burden profile from Top position of the
burden from wall to center of the furnace.
BURDEN SPRAY WATER
Elevation : 43 mtr

TOP SPRAY WATER FLOW

298m3/hr
Pressure-9.3bar
(Max. Temp @ 300*C)

Purpose is to control the top

temperature

8 points were provided

 STEAM INJECTION (3nos) NITROGEN(3nos)
Elevation : 43mtr

STEAM INJECTION (3nos)

NITROGEN(3nos)

The Main Purpose of Steam injection and Nitrogen in the Furnace is during
shutdown for CO Neutralization
IMPACT BURDEN PROBE
Elevation : 42mtr (1 Nos.)
THERMOCOUPLE

 SKIN FLOW THERMOCOUPLE  STAVE THERMOCOUPLE

Elevation Elevation
39mtr. (US-59) : 8 37mtr. (US-58) : 8
37mtr. (US-58) : 8 35mtr. (US-57) : 8
35mtr. (US-57) : 8
REFRACTORY WEAR
MONITORING ROD (28nos)
In order to check the Refractory Wear of the furnace inside wall these are used.
Nos
ELEVATION

1 17 mtr 4

2 19 mtr 4

3 21 mtr 4

4 24 mtr 4

5 27 mtr 4

6 30 mtr 4

7 34 mtr 4
PRESSURE PROBES
There are 7 sets of Pressure probes dedicated at different elevation to derive
the Differential pressures such as upper DP, middle DP & Top DP.
Nos
ELEVATION

1 17 mtr 4

2 19 mtr 4

3 21 mtr 4

4 24 mtr 4

5 27 mtr 4

6 30 mtr 4

7 34 mtr 4
REFRACTORY THERMOCOUPLE (56)

Nos
ELEVATION

1 17 mtr 8

2 19 mtr 8

3 21 mtr 8

4 24 mtr 8

5 27 mtr 8

6 30 mtr 8

7 34 mtr 8
 Tuyere Ducts and Thermocouple

Bustle Main
Gooseneck

Upper
Compensator

Lower
Compensator

Blow
Pipes

TUYERE and Blow pipe assembly 38 UNDER TUYERE THERMOCOUPLE 38

 HEARTH STAVE

ROW Number of
No. coolers

HS- 5 52 staves
HS- 4 52 staves
HS- 3 52 staves
HS- 2 52 staves
HS- 1 52 staves

NO OF HEARTH STAVE : 5*52=260

+4 (SALAMANDER HOLE).
 UMS UMS- 48-56 40

LMS LMS- 39-47 40

ULS ULS- 31-38 40

LLS LLS- 22-30 40

BE BE-15-21 40

BO BO-05-14 40

BO-04 76

TU TU-03 76

TU-02 38
TUYERE
TU-01 38

NO OF COPPER PLATE :

38+38+76+76+(40*52) = 2308
 TOTAL NO OF STAVES IN UPPER STACK : 4*40 = 160

US- 60

US- 59

US- 58

US- 57

ROW No. Number of coolers

US- 60 40 staves
US- 59 40 staves
US- 58 40 staves
US- 57 40 staves
Furnace bottom Thermocouple

Bottom Plate Thermocouple : 4

Elevation: 4.1 Mtr.

At an angle of 630, 1170, 2430, 2970

Hearth Bottom & Hearth wall Thermocouple

Hearth bottom & Hearth wall thermocouples supports the operator to check the
Hearth lining condition & its wear pattern.

Hearth wall Thermocouple : 28

Location Elevation Nos.
(Mtr.)
Hearth Bottom Thermocouple : 24
Location Elevation Nos. Hearth Wall 1 6.7 8
(Mtr.) Hearth Wall 2 7.6 8
Hearth 5.7 8 Hearth Wall 3 8.6 4
Hearth 5.2 8 Hearth Wall 4 9.8 4
Hearth 4.7 8 Hearth Wall 5 11.3 4
Furnace Grouting Points
Grouting points are given to impinge grouting material periodically
Hearth Stave Grouting Nozzles: 64 Stave Grouting Nozzles: 32