Effect of Hearth Liquid Level on the Productivity of Blast Furnace

Agrawal, Ashish; Kothari, Anil Kumar; Rao, K. Ramakrishna; Padmapal,; Singh, Manish Kumar

doi:10.1007/s12666-018-1545-z

Cited by 5 publications

(4 citation statements)

References 43 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Furthermore, the particle movement within the deadman is of great interest, as it is expected to greatly influence the bed permeability. 2) The combination of CFD with the Discrete Element Method (DEM), 12) in which particles are treated as individual entities, is especially suited for simulation of the blast furnace hearth, as it allows for the simultaneous evaluation of the liquid flow and solids movement. Additionally, through use of a multiphase CFD method such as Volume of Fluid, 23) the free surface of the liquid iron can be accounted for.…”

Section: Large-scale Blast Furnace Modellingmentioning

confidence: 99%

“…On the other hand, a completely stationary deadman might be prone to accumulation of fine cokes and char, leading to a non-desirable low-permeability bed state. 2,3) Figure 11 shows the temporally and radially averaged solids velocity profile obtained from the base case 4. One can clearly distinguish between the actively flowing layer towards the raceway region and the deadman.…”

Section: Deadman Coke Flowmentioning

confidence: 99%

See 1 more Smart Citation

Large-scale VOF/CFD-DEM Simulation of Blast Furnace Hearth Dynamics

et al. 2022

View full text Add to dashboard Cite

In this work, large-scale simulations of the blast furnace hearth are presented, conducted using a model combining Computational Fluid Dynamics, the Volume of Fluid method, and the Discrete Element Method. Using a 5 m diameter, full-3D geometry, the influence of burden weight, bi-disperse packing, and blocked tuyeres on the liquid and solids flow within the hearth are investigated. Horizontal and vertical porosity profiles are presented, and the influence of the dynamic liquid level on the state of the deadman is evaluated. The liquid iron flow during tapping is visualised, and the influence of a coke-free space on the flow pattern is analysed. The magnitude of the circumferential flow through the corner of the hearth is analysed, and found to decrease with increasing burden weight pressure and coke diameter in the bed centre. A significant influence of the dynamic deadman on the liquid flow pattern is found, especially in case of a floating deadman. In addition to the liquid flow, the solid coke flow towards the raceways is analysed. Two pathways for coke particles towards the raceway are uncovered, one path through the actively flowing layer above the deadman, and a second path moving through the deadman and entering the raceways from below. The balance between these two mechanisms was found to change during the tapping cycle. Lastly, implementations for heat and dissolved carbon mass transfer are presented, and demonstrated using a full-scale 10 m hearth simulation. Additional closures for heat and mass transfer rates are required, but the current model is found in good shape for future work.

show abstract

Section: Large-scale Blast Furnace Modellingmentioning

confidence: 99%

Section: Deadman Coke Flowmentioning

confidence: 99%

Large-scale VOF/CFD-DEM Simulation of Blast Furnace Hearth Dynamics

et al. 2022

View full text Add to dashboard Cite

show abstract

“…The casting or drainage rate can be defined as the rate at which the liquid hot metal and slag are being tapped from the BF hearth. The casting rate mainly affects the resistance in the lower part of the furnace that directly influences the production rate [28]. With the increased slag level in the hearth, the casting rate must be increased to control the slag level without creating any extra resistance in the furnace.…”

Section: Effect Of Casting Parameters On Slag Propertiesmentioning

confidence: 99%

Means to cope with the higher alumina burden in the blast furnace

Agrawal

Das

Singh

et al. 2020

Ironmaking & Steelmaking

Self Cite

View full text Add to dashboard Cite

The stability of the blast furnace (BF) process depends on the quality of raw materials charged into the BF. Apart from various process variables, slag viscosity and slag fluidity are key parameters that require due attention for the stable BF operation. The varying Al 2 O 3 content in slag increases the viscosity of slag and thus hinders the separation of slag from hot metal during the casting process. This leads to the deterioration of hot metal quality because of the entrapment of slag during the slag-metal interfacial reaction. In this work, an attempt is made to utilize the high alumina content raw materials and to reduce the Al 2 O 3 content in the final slag. The high alumina content in slag increases the liquidus temperature and viscosity of slag and causes an adverse effect on BF operations. To countermeasure the effect of alumina, slag volume is increased and basicity along with MgO was increased. It has been demonstrated that MgO addition as a flux is effective for compensating the effect of a high alumina burden. By increasing the MgO in slag, fluidity was maintained to ensure easy separation of slag from hot metal.

show abstract

“…5) Furthermore, the relationship between the EMF signal and the liquid level is so challenging to interpret that a reliable real-time liquid level system based on EMF sensors is yet to emerge. 11) Compared to the EMF-based method, the greatest advantage of the strain gauge method is that it is able to calculate real-time absolute liquid level [8][9][10] . However, the installation of strain gauges is more difficult to accomplish not only due to the complicated bonding or welding procedure but also due to the higher fragility in harsh environments.…”

Section: Introductionmentioning

confidence: 99%

Real-Time Hearth Liquid Level Monitoring Systems to Optimize Tapping Strategies in Blast Furnaces

Chang¹,

Ho²,

Tai³

2023

ISIJ Int.

View full text Add to dashboard Cite

The hearth liquid level is essential for optimizing the tapping strategies. Considering that the tapping strategy is crucial for the stable operation and longer campaign life of a blast furnace, a hearth liquid level monitoring (LLM) system is developed by using the strain gauge method together with finite element analysis. Since 2020, the real-time LLM system has been successfully implemented at Taiwan's China Steel Corporation (CSC) on three blast furnaces (BFs): two (BF3, BF4) have the spray-cooled hearths with four tapholes, and the other (BF2) has a stave-cooled hearth with two tapholes.The liquid level history is visualized with other tapping information; therefore, the tapping strategies can not only be optimized in regular casts but are also more flexible in coping with unexpected incidents. With the aid of a real-time LLM system, the tapping strategies has been significantly improved by (a) making data-driven decisions to open and close a cast, (b) making quick decisions to interrupt a cast, (c) optimizing the gap time of one-sided casting, (d) using the optimal remedy for rapidly increased liquid level, (e) improving the hearth state during the blast furnace operation, etc.The statistical analysis on the completed casts shows that the LLM system does significantly contribute to a more smooth and stable tapping operation: for BFs 2, 3, and 4, the deviations of cast duration are decreased by 31, 26, and 22 %, and the mean values of slag-iron ratio are increased by 8.3, 3.5, and 3.8 %, respectively.

show abstract

Effect of Hearth Liquid Level on the Productivity of Blast Furnace

Cited by 5 publications

References 43 publications

Large-scale VOF/CFD-DEM Simulation of Blast Furnace Hearth Dynamics

Large-scale VOF/CFD-DEM Simulation of Blast Furnace Hearth Dynamics

Means to cope with the higher alumina burden in the blast furnace

Real-Time Hearth Liquid Level Monitoring Systems to Optimize Tapping Strategies in Blast Furnaces

Contact Info

Product

Resources

About