Failure mode and mechanism of a blast furnace tuyere

Zhang, Jun; Wang, Ruidong; Hu, Rong; Zhang, Chao; Li, Guangshi; Zhang, Kun; Wu, Wenhe; Lu, Xionggang

doi:10.1016/j.engfailanal.2022.106294

Cited by 20 publications

(5 citation statements)

References 9 publications

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“…Molten steel is poured from the furnace into a ladle and then into the tundish, from where it enters the continuous casting machine through a shroud that is termed as the submerged entry nozzle (SEN) [ 29 ]. The outer SEN lining is thermal spray coated to avoid damage due to molten steel slag and to prevent clogging, as represented in Figure 9 and Figure 10 [ 23 , 43 ].…”

Section: Thermal Spray Applications In Iron and Steel Industrymentioning

confidence: 99%

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Applications and Developments of Thermal Spray Coatings for the Iron and Steel Industry

et al. 2023

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The steel making processes involves extreme and harsh operating conditions; hence, the production hardware is exposed to degradation mechanisms under high temperature oxidation, erosion, wear, impact, and corrosive environments. These adverse factors affect the product quality and efficiency of the steel making industry, which contributes to production downtime and maintenance costs. Thermal spray technologies that circumvent surface degradation mechanisms are also attractive for their environmental safety, effectiveness and ease of use. The need of thermal spray coatings and advancement in terms of materials and spray processes are reviewed in this article. Application and development of thermal spray coatings for steel making hardware from the molten metal processing stages such as electric arc and basic oxygen furnaces, through to continuous casting, annealing, and the galvanizing line; to the final shaping process such as cold and hot rolling of the steel strips are highlighted. Specifically, thermal spray feedstock materials and processes that have potential to replace hazardous hard chrome plating are discussed. It is projected that novel coating solutions will be incorporated as awareness and acceptance of thermal spray technology grows in the steel making sectors, which will improve the productivity of the industry.

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Section: Thermal Spray Applications In Iron and Steel Industrymentioning

confidence: 99%

“… A typical application of thermal spray coatings in protecting blast furnace tuyeres, ( a , b ) overall views, ( c ) front end, and ( d ) inner wall of a tuyere of blast furnace, adapted with permission from [ 29 ]. 2022, Elsevier.…”

Section: Figurementioning

confidence: 99%

Applications and Developments of Thermal Spray Coatings for the Iron and Steel Industry

et al. 2023

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“…For the coating, the thermal conductivity of the coating has the greatest influence on its temperature, followed by the blast furnace ambient temperature, coating thickness, and water flow rate. When the temperature of the tuyere copper substrate is maintained above 473 K for a long time, the physical properties of the tuyere sleeve will decrease significantly due to the growth of internal copper grains [1,16,30]. Therefore, in actual production, it is necessary to maintain a high water speed and control the blast furnace's ambient temperature within a safe range.…”

Section: Investigation Of the Influence Of Annular Wear-resistant Lay...mentioning

confidence: 99%

“…This finding highlights the potential for extended tuyere lifespan. Zhang, J. et al [16] proposed the application of wear-resistant coatings to protect the front end and inner wall of the tuyere, with the aim of extending its service life. Zhiyu Chen et al [17] used CFD simulations to investigate the temperature field of the tuyere small sleeve with Ni60A coatings containing different copper contents.…”

Section: Introductionmentioning

confidence: 99%

Optimization Study of Annular Wear-Resistant Layer Structure for Blast Furnace Tuyere

Zhu

Zhang

Zong

et al. 2023

Metals

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A new tuyere small sleeve coating structure that balances the high thermal conductivity of the copper substrate with the high wear resistance of the protective layer was developed in this paper. This structure can achieve a low-carbon blast furnace by reducing the heat loss from the tuyere. The 3D model was established via Solidworks for modeling and Ansys for numerical simulation, the temperature field of the annular wear-resistant layer structure tuyere small sleeve with different widths of the wear-resistant layer was analyzed and compared with the temperature and stress field of traditional tuyere small sleeve. The results show that the design of the annular wear-resistant layer structure of the tuyere small sleeve is more effective. The new annular wear-resistant layer structure for the tuyere small sleeve results in a decrease of 24 K in the average temperature of the wear-resistant coating. The comparison of this structure with tuyere sleeves without wear-resistant coatings shows a 16.7% reduction in heat loss, improves the wear resistance of the tuyere, providing new technological ideas for low-carbon blast furnace production. Compared with the tuyere sleeve completely covered with a wear-resistant coating, the maximum thermal stress of this structure decreased from 624.98 Mpa to 427.99 Mpa, resulting in a reduction of 31.5%, which is beneficial for the service life of the tuyere sleeve. The copper surface temperature of the new tuyere small sleeve is in a safe range when the temperature is below 2273 K.

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“…However, copper components are highly susceptible to being damaged in extreme environment due to poor wear resistance. For example, the blast furnace tuyere for iron-making can be easily worn by high-speed pulverised coal, leading to a great decrease in its service life [2]. Therefore, the wear resistance properties of copper materials under extreme conditions need to be improved by surface engineering technology [3].…”

Section: Introductionmentioning

confidence: 99%

High-temperature wear behaviour of plasma cladded WC/Ni60A composite coating on copper

Zhang

Wang

et al. 2023

Materials Science and Technology

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With the aim of improving the surface properties of copper, WC/Ni60A composite coatings were successfully prepared by plasma cladding. A good metallurgical bonding was formed between composite coating and copper substrate. The large amount of dispersed WC and W2C phases in the coating significantly increased the microhardness (17 times that of the copper substrate). With the rise in temperature, the wear resistance of the coating first increased and then decreased. At 400°C, the coating had the best wear resistance due to the lubricating effect of the oxide layer. However, due to the simultaneous occurrence of various wear mechanisms, the wear resistance at 600°C was significantly reduced, so the service temperature must be controlled below 600°C.

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Failure mode and mechanism of a blast furnace tuyere

Cited by 20 publications

References 9 publications

Applications and Developments of Thermal Spray Coatings for the Iron and Steel Industry

Applications and Developments of Thermal Spray Coatings for the Iron and Steel Industry

Optimization Study of Annular Wear-Resistant Layer Structure for Blast Furnace Tuyere

High-temperature wear behaviour of plasma cladded WC/Ni60A composite coating on copper

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