1 TATA STEEL OVERVIEW

Tata Adde recen 7

Steel d). tly MTP
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2
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plans privil and aged
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emer not mater achie
ge as by ials ve

3
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for p p
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mic t e n

4
 d f n  T
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5
 t whic This and
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6
in icant and the
whic contri help natio
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most to enric
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7
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Tata Steeli ructio comp
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s (the Tata Retail
prod world Struct Value
ucts ’s ura Mana
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and Rolle ructio the
cold d n needs
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and Shakt The butor
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8
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16
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17
 2 OUR CUSTOMERS
The hot metal (pig iron) produced at the BFs are loaded in torpedo ladles and sent to the steel melting
shops for onward processing. Open top ladles are also used for the purpose of transporting hot metal but is
currently being phased out.

The torpedo ladles are emptied at the Steel Melting Shops – LD1 & LD2 into hot metal transfer ladle.

Pouring out of hot metal from torpedo

The hot metal transfer ladles is used to transfer & pour hot metal into the LD vessel. In the LD vessel steel
is made.

LD vessel Charging of LD vessel

18
Steel Melting Shops – LD1

Modernisation Phase I Program updated the steelmaking facilities, marking an important milestone in the
history of Tata Steel. The 29 month program was formally launched on Dec. 8, 1980, and it was
completed in March 1983 with the commissioning of the 1.1 million tonnes per annum Basic Oxygen
Furnace, i.e. L.D. Shop now LD Shop 1. It had the following main features:
 Two 130 ton basic oxygen converters, with flux charging system, gas cleaning and gas recovery
plant. M/s Davy Mckee of U.K. had supplied the main equipments. The L.D. converters were
started as top blown oxygen process. They have now been changed to combined blowing using the
TBM (Thyssen Blowing Metallurgy) process.
 One 6-strand Continuous Casting Machine supplied by M/s Concast AG and Concast India.
 The 6-strand Continuous Casting Machine of EOF was relocated at LD-1 in 1996 to augment CC
Capacity.
 The new shop had marginally increased the overall saleable steel production of Tisco from 1.524
to 1.740 million tones per annum when it became operational fifteen years ago.
 LD1 was provided with one Desulphurisation Station originally. During the 1 MT augmentation
project a second DS unit was set up. Currently a third DS unit is being added as part of 1.8 MT
augmentation project.

Steel Melting Shops – LD2 (LD2 & SC)

L.D. Shop No. 2 (LD-2) was set up as a part of Modernization Phase-III Program and commissioned
during 1993-94. The shop was further modernized during 1998-99 in the Phase IV Modernization
Program to augment its capacity to 2.18 million tons slabs per annum.

LD 2 has been provided with the following:

 Torpedo Unloading Station – Hot metal is unloaded in hot metal transfer ladles (140T) at the
torpedo unloading pit. From here hot metal is transferred to the Desulphurisation Station with the
help of EOT cranes.
 Desulphurization Station – Hot Metal Desulphurisation units play a vital role in helping producing
low sulphur grades for meeting the final customer requirements. This is important because the hot
metal production strategy at Tata Steel is different compared to most of the plants around the
world. While most plants operate at low sulphur (0.020 – 0.040 %), hot metal produced at Tata
Steel contains about 0.060 – 0.090 % sulphur. This enables low basicity operation at BF which
reduces the slag rate & increases productivity. For hot metal desulphurization, two desulphurizing
materials are used: Calcium carbide and magnesium (lime is also added together with carbide).
Co-injection process is employed at LD2&SC and the percentage of heats that are desulphurized is
~98%. The desulphurization compounds are in powder form and are contained in silos which have
nitrogen atmosphere in it. Nitrogen is used as a carrier gas to transport these compounds through
silo to injection dispensers and from injection dispensors to injection lance.
 LD Vessel - The converter section consists of three 140 ton LD converters. Converter#1 was
commissioned in October 1994, converter#2 in December 1995 and converter#3 in October 1998.
Two converters are operated and one remains as stand by. The charge in the converter consists of
135 T Hot metal and 10 T Scrap. Oxygen is blown on the surface of the hot-metal in the converter
through a six hole lance at 450 Nm3/min. For better reaction and homogeneity during the blow,
inert gas (argon/nitrogen) is purged from the bottom through eight TBM tuyeres. During the blow,
flux (lime) is added to make slag with the oxides. Iron ore is also added as a coolant during the
blow. The liquid steel is then tapped into a ladle.

19
 TQM/AQUIP/04-01 dt. 01/04/01
MEMORANDUM OF UNDERSTANDING
Year 2002 – 03
Customer Dept : L.D. # 2 & Slab Caster Supplier Dept : A – F Blast Furnaces

A) REQUIREMENT RELATED TO PRODUCT

Sl. No MOU Parameter Unit of Base level Target Review

measure Level Frequency
PARAMETERS
PRODUCT /
DELIVERY

1. Hot Metal “Si” % 0.89 0.70 Monthly

2. Heats with HM Si >1.00 % % 20 10 Monthly
3. Heats with HM S >0.070 % % 40 20 Monthly
4. Heats with HM S >0.100 % % 10 5 Monthly
5. No of torpedos < 140t Nos / week 5 2.5 Monthly
6. Hot Metal temperature < 1250’C % 5 2.5 Monthly

B) REQUIREMENT RELATED TO SERVICE

Sl. No. MOU Parameter Unit of Base level Target Review
PARAMETERS

measure Level Frequency

PRODUCT /
DELIVERY

1. Customer visits Nos / week New 01 Monthly

2. Slag carryover Visual New 05Torpedo Monthly
Heavy slag

Supplier Department Customer Department

Signature : Signature :

Name : S.K. Roy Name : H. Jha

Designat on : Chief A-F Blast Furnaces Designation : Chief LD # 2 & SC

A typical MOU – between A-F BF & LD1

MEMORANDUM OF UNDERSTANDING
Year 2002 – 03
Customer Dept : L. D. Shop # 1 Supplier Dept : A – F Blast Furnaces

A) REQUIREMENT RELATED TO PRODUCT

Sl. No MOU Parameter Unit of Base level Target Review

PARAMETERS
PRODUCT /
DELIVERY

measure Level Frequency

1. Hot Metal “Si” (>1.3 % should be nil) % 0.96 0.90 Monthly
2. Hot Metal “S” ( > 0.100 % should be nil) % 0.077 0.07 Monthly
3. Slag Carry Over % 1.1 0.60 Monthly

B) REQUIREMENT RELATED TO SERVICE

Sl. No. MOU Parameter Unit of Base level Target Review

PARAMETERS
PRODUCT /
DELIVERY

measure Level Frequency

1 Hot Metal Temp.(<1200OC – nil) Deg C 1250 1260 Monthly
2. O2 Lancing of Ladles % 38.20 32 Monthly
3. Visit for Interaction No/Week 1 1 Monthly

Supplier Department Customer Department

Signature : Signature :

Name : S.K. Roy Name : P.K. Ghose

Designation : Chief A-F Blast Furnaces Designation : Chief LD # 1

20
 A typical MOU – between A-F BF & LD2
Expectations from the Customer
With the commissioning of the “H” blast furnace, steelmakers at Tata Steel, are eagerly awaiting to
receive hot metal of a quality ,which, they have always desired. With “H’ fce. being made to international
standards in terms of size and facilities, the expectations are still higher.

In Tata Steel, we have been operating with high input hot metal phos, primarily , due to our input raw
material constraints , which is interestingly, our great strength in ensuring that we are one of the lowest
cost producers of hot metal and steel. We have over a period of time developed the expertise to produce
low phos steel from high phos hot metal. With the introduction of hot metal desulphurisation units and co-
injection in the steelmaking shops, we are able to reduce the sulpur in the hot metal prior to charging in
the LD Vessels incurring an additional cost.

Due to the inherent high hot metal silicon and phos, we do operate, at slag volumes and lime
consumptions which are quite adverse compared to international standards. Apart from the additional
metallurgical load on the vessel refractory lining and high cost, it has detrimental effect on the quality in
terms of the cleanliness of steel due to higher oxygen levels in steel, higher additions of de-oxidisers and
slag carry over.

In the flat product business, the customers quality requirement are very stringent, the need is to produce
steel with high degree of cleanliness and low phosphorous steels of less than 0.012%. The customers
demand dictates that the input to the steelmelting shop is controlled.

Hence the expectation from “H” Fce is as follows :

Hot Metal Silicon - 0.4 to 0.6 %

Hot Metal Phos - 0.12 % max.

Hot Metal Sulphur - 0.04 to 0.045%

Hot Metal temp - 1330 to 1350 Deg C. ( at the shop)

21
 3 Blast Furnace Ironmaking

3.1 Introduction to the blast furnace plant

Blast Furnace is a counter current reactor based shaft furnace. Unlike steel melting shops, it is a
continuous operating plant. Charging to BF and casting of metal & slag from BF is a considered as a batch
process. The main producing unit (i.e. BF) is continuously operating unit.

Figure 3.1: Blast furnace facilities

22
1. Cast house 2. Venturi 3. Dust catcher
4. Gas cooler 5. Bells 6. Receiving hopper
7. Downcomer 8. Bleeder valves 9. Offtake
10. Uptake 11. Stack 12. Stove
13. Hot blast main 14. Cold blast main 15. Mixer main
16. Skip bridge 17. Highline 18. Bins
19. Skip 20. Hoist house 21. Cinder notch
22. Iron notch 23. Drill machine 24. Slag runners
25. Slag pots 26. Iron ladles 27. Iron runners
28. Trough 29. Mudgun 30. Tuyeres

23
 Figure 3.2: Schematic description of a blast furnace

As can be seen in Error: Reference source not found & Figure 3.2, typical blast furnace auxiliaries
include:
 Raw material handling system
o Raw material feeding system to stock house
o Stock house
 Charging system
o Batching system consisting of screening system, weighing system
o Transporting system to transport the burden material to furnace top – skip, conveyor
o Discharging system to discharge burden material inside BF – PW top, bell top
 Hot blast system
o Blowers to deliver cold blast
o Flow regulating system
o Hot blast heating plant
 Gas cleaning plant
o Dry dust removal
o Wet scrubber
o Top ghas recovery turbine
 Cast House
 Fuel Injection
24
Raw material handling system - To charge raw materials inside the BF there is an elaborate system for
receiving & storing of raw materials. This is called the raw material handling system. It starts with the
various receiving systems for individual raw materials. Raw materials are typically received from sinter
plants, coke plants, pellet plants, storage yards etc. Each type of material is stored in separate bins in the
stock house.

Charging system - Charging system charges coke and iron bearing burden (sinter, pellets, lump ore)
along with fluxes are charged in different layers at the top. These are then screened and weighed as per
operator defined charging sequence and transported to the top of the furnace using a skip or a conveyor
system. Most commonly used charging system to discharge & distribute the burden inside the BF are –
PW top or Bell top.

With bell-type charging equipment , the raw materials reach the big bell when the small bell opens. Once
the small bell is emptied it closes. After the required material is received on the big bell, the beg bell opens
to discharge the burden inside the BF. With bell-less charging equipment , the raw materials are dropped
into the furnace through a rotating chute which can change angles allowing more flexibility in precise
material placement inside the furnace.

Hot Blast System - The hot blast system normally refers to hot blast stoves only. These are cylindrical
units about 8 - 12 m in diameter and some 35 - 55 m in height. The hot stove is a type of heat exchanger in
which the heat produced by combustion of the BF gas is stored in the checker-work chamber, after which
cold air is blown through the hot checker-work to produce the preheated hot air blast to the furnace. Three
or four stoves are operated on alternate cycles, providing a continuous source of hot blast to the furnace.
They have either internal or external chamber for combusting fuel gases for heating up the stove. The cold
blast is supplied to stoves from a blower house. Due to compression the temperature of the cold blast is
much higher than the ambient and is about 150 – 250 deg C.

Cold blast at 150 - 250°C from the blower houses after heating in the hot blast stoves to 1000 - 1300°C is
injected into the furnace at the lower part through tuyeres. In front of each tuyere the hot blast burns coke
and forms carbon monoxide which ascends in the furnace and reduces the iron ores.

Gas Cleaning Plant – A large BF is usually operated with a top pressure of about 1.5 – 2.5 bar gauge
pressure. To recover the energy from the large volume of high-pressure exhaust gas, the BF is equipped,
after dust removal, with a top-pressure recovery turbine, for generating electric power by utilizing the
pressure difference between the furnace-top and gas storing holder. (Refer chapter - )

Cast house – Liquid iron and slag from the taphole flow down a deep trench called a "trough". Set across
and into the trough is a block of refractory, called a "skimmer", which has a small opening underneath it.
The hot metal flows through this skimmer opening, over the "iron dam" and down the iron runners. Since
the slag is less dense than iron, it floats on top of the iron, down the trough, hits the skimmer and is
diverted into the slag runners. The liquid slag flows into slag cars or into slag pits and the liquid iron flows
into refractory lined ladles known as torpedo cars.

Blast furnaces in which pulverized coal is injected from the tuyeres are provided with equipment for
pulverizing the coal and feeding it under pressure

In the hearth, molten metal is collected along with slag is collected. Hot metal being heavier and more
fluid settles to the bottom of the hearth in almost all cases. Slag floats due to its lower density on the hot
metal bath. While both are possibly at the same temperature when entering the heart, liquid hot metal
loses some heat because of conductivity and reduction of oxides and is tapped at around 1470 - 1500°C.
Slag being poor in conductivity loses less heat and is tapped at a temperature about 50°C higher. The
tapping, though batch process has to be done regularly to ensure that liquid level does not build up inside

25
the hearth. The aim of cast house tapping management is to keep the hearth with minimum liquid
level always.

The outputs of BF process are pig iron (molten form), slag (preferably granulated), top gas and flue dust.
BF Ironmaking revolves around controlling & optimising - slag chemistry & its fluidity. Good slag
making means 80% work of Ironmaking done. However, slag is a by product of the process with a well
defined composition. It is mainly used as a raw material in cement industry, for road construction, land
filling etc. Other possibilities of slag usage are to produce slag wool and foamed slag.

3.2 Blast furnace design

The blast furnace has a vertical cylindrical structure externally covered with a shell of thick steel plate and
internally lined with refractories. The refractory structure is cooled by water-cooled metal components
called staves, which are embedded between the shell and the refractories. .

Figure 3.3. : Blast furnace sectional drawing

26
The furnace body or profile consists of five parts

 top or throat, which is a straight cylinder;

 shaft or stack, which tapers outward from the top;
 belly, which is a straight cylinder;
 bosh, which tapers inward toward its bottom;
 hearth, at the bottom of the furnace, which is a straight cylinder

The shaft, belly, and bosh are usually lined with chamotte brick and silicon-carbide brick, and the hearth is
lined with carbon brick. Depending on the size of the furnace, the side wall of the hearth is radially fitted
with some 14 to 42 of water-cooled copper tuyeres, which are used to inject the hot blast into the furnace
from the hot stoves through the hot-blast main and blowpipes. A tuyere apparatus of a modern blast
furnace is fitted with special lances for injection of auxiliary fuels and other additives. Tap holes for
discharging hot metal and cinder notches for discharging slag are also installed in the hearth section. Some
large blast furnaces have 3-4 tap holes for metal and none for slag because specific slag volume is low due
to high quality burden and it is discharged fully with hot metal.

Evaluation of blast furnace dimensions

Blast furnace process was created by way of experience 650-700 years ago as a result of the evolution of
bloomery furnaces.

From 1860 onwards blast furnaces went through a great phase of evolution, Figure Fig. 2. 4.

Figure 3.4: Development of blast furnace dimensions

During the years 1860 and 1960 the diameter of the furnace hearth increased from 0.9 to 8-9 m with
production of 25 and 1500-2000 t hot metal per day respectively. Since the 1960s till the 1980s the hearth
diameters have almost doubled, the furnace volume and the productivity increased about 2.5 and 5 fold
respectively.

The largest blast furnaces at present are about 80 m in total height, with a inner height of about 33-34m

27
and a maximum internal diameter of about 16-17m, and have an internal volume of about 5,000-5,500m3.
A furnace of this size can produce approximately 10,000- 13,000 tons of hot metal a day.

Working, inner and total volume are used to characterize the size of the blast furnace. Working volume is
the volume of the working height ( Figure ). Working height is the distance from the stockline (more
exactly from 1 m below the large bell in low position or from 1 m below the rotating chute in vertical
position) to the tuyere level. Inner or useful volume is the volume of the inner height which is the distance
from the stockline to the taphole level. The total height is made up of the inner height plus the distance
between the stockline and the charging platform.

Table 3.1 : Dimensions of some large blast furnaces.

Since the middle of 1980s the increase in the blast furnace size stopped. The inner volume in the range
3000 to 5000 m3 is optimal from the operating conditions and production costs points of view.

The blast furnace profile has evolved through experience and has undergone a considerable change. An
analysis of the evolution of the furnace profile (Figure ) shows an initial long bosh without its belly to the

28
introduction of the latter with gradual shortening of the bosh. Furnace height/diameter ratio decreases
slowly but steadily with the rise of the furnace dimensions (Table 2.2).

BF - Structure
The blast furnace design has eventually evolved from a “mantle supported / lintel supported design” in the
mid –twentieth century to a “free standing design

The ‘free standing’ design with tower structure provides many benefits above the ‘mantle supported’ type
and can be summarized as below:
o For the same hearth dia more no. of tuyeres are possible.
o Provides an expanded working platform at the tuyere level allowing better access for
furnace monitoring and more space for mechanized maintenance in this area
o The stack platforms are wider and safe working areas, giving the access for long life
maintenance practices.

BF - Top Charging System

The furnace top charging system also has developed hand in hand. The evolution of the top charging has
taken place as follows:

o Two bell top

o Two bell top with Variable throat armour

o Bell less top

At Tata Steel, B Blast Furnace has the top charging of first type, A, C & D Furnaces of the second type
and F & G of the third type

2-bell charging Bell-less top charging

Fig 3.5: BF Top Charging systems

The BELL-LESS TOP charging system is the third generation of charging system. It is the only system
which is able to direct material to any point on the stock line surface and can be used to create any burden
profile. The burden can be charged to profiles independent of the angle of repose of the material. The first

29
industrial bell-less prototype went into operation in August 1971 at Thyssen and gained immediate
acceptance. Today this system is used for more than 60% of the pig iron production in the world.

The well proven advantages offered by the Bell Less Top are :
o Total fuel consumption savings
o Higher productivity
o Higher top pressure (compared to McKee type top)
o Extended blast furnace campaign
o Improved and consistent hot metal quality
o Optimal gas flow at high coal injection rates
o Increased availability because of lower maintenance downtime

There are several adaptations of the Bell Less Top for various sizes of Blast Furnaces. The various types
of BLTs are enumerated below:

Central Feed BLT with Rotating Compact Bell Less Top: The compact
Receiving Hopper form of the bell-less top was used to
allow the integration into the
existing Blast Furnace top and the
skip incline and with only minor
modifications of the upper
structure. This is generally used for
middle and small sized furnaces. F
Blast Furnace at Tata Steel has an
adapted CBLT

Fig 3.6: Types of BLT

Parallel Hopper top BLT

30
BF – Cooling system
Just as BF iron making very old so is the cooling system. As per available records cooling in BF was first
introduced in 1884. The period 1900- 1920 saw development of cooling system in hearth & bosh area. As
the furnace size & productivity increased, the furnace was subjected to higher heat loads. In the period
1930-1940 cooling system was applied to shaft of BF. 1950–1960 saw major development in cooling
system as the furnace became larger, introduction of high top pressure, fuel injection, higher hot blast
temperatures, higher productivity.

The earliest cooling systems were very simple system. They were shower type or jacket cooling type.
System involved heat extraction through shell to cooling medium. These are still used in low cost furnaces
(MBF), at times even the whole furnace. The drawback with this system was the high thermal stress on the
shell. Integrity of the shell was also put to risk. This system is successful in areas of low heat flux like
hearth wall, area around tuyeres, upper part of furnace etc. For example Thyseen uses jacket cooling for
hearth cooling. This allows installation of thicker refractory inside the hearth shell with jacket outside the
shell. Shell does not need any holes and hence does not have any gas leakage or stress concentration
points. Drilling for additional thermocouple can be done practically anywhere.

To meet cooling necessity of areas with high heat flux, cooling plates and staves were developed.
These provided intense cooling without subjecting the shell to risk. Both systems developed in parallel
and have the cooling medium in a cooling system placed inside the furnace. Both can sustain long
campaign live.

Besides the shell, the under hearth also requires cooling in large BF’s. In small BF’s hearth wall cooling
system caters to under hearth cooling. In larger BF’s, separate under hearth cooling is provided. Air has
been tried as a cooling medium. Generally water through pipelines is used in under hearth cooling.

Plate cooling was developed for cooling above tuyere level. The plates extend inside the furnace and
support the refractory lining besides cooling it. This is not applied in the hearth. The plates can be changed
easily from outside in case of damage. The ease is subject to good condition of the arch type self
supporting brick design inside the furnace. The plates have a protective refractory lining which it cools
extensively. This arrangement has high retained heat in refractory lining reduces quantum of accretion
layer formation. To vary the cooling intensity, the pitch distance is varied. Lining uniformity is easily lost
especially where the cooling is not intense or in areas of thermal spalling (throat). Shell plate design
becomes very difficult due to large openings - especially when the pitch distance is low. There are stress
concentration points at corners of opening in shell. The piping is complicated. Mantle area becomes very
critical in mantle-supported furnace.

In the two pass coolers, the nose velocity & heat extraction is taken care of but the body area suffers. By
increasing the number of pass, the body cooling efficiency is increased

Stave cooling developed in parallel to plate cooling. These are flat cooling members parallel to the shell
embedded between the refractory & shell. The initial applications were:
 Areas of high heat flux requiring low pitch distance between cooling plates – bosh & belly
 Difficult to access areas – hearth and around tuyere
 Areas which did not qualify for plate cooling – hearth
 Areas requiring uniform cooling through out – bosh, belly, hearth

31
These subsequently found application in areas prone to early deterioration – throat. Staves provided a
good stable surface for better charging control. Extending the logic the complete furnace started having
stave coolers. This is the concept applied in most modern large BF’s.

Initial staves were all cast iron based. The development of cast iron staves can be categorised in 4 clear
generations.

1st Generation Staves: These were grey cast iron based on / capable of evaporative cooling. The riser
pipes (for water) were at a angle greater than 30 deg (up to 60 deg) to horizontal after entering stave and
before leaving. These staves lacked edge cooling. Due to evaporative cooling capability these were huge
in size. They were ideal as it could continue to function for a long time even when the water recirculation
systems failed.

Figure 3.7: First generation staves

2nd Generation Staves To cool edges 90 deg turn in pipes were introduced. They were also provided with
shelf cooling pipe. Along with this forced circulation systems became essential and evaporative cooling
was not possible. These were made of ductile cast iron.

Figure 3.8: First generation staves

32
3rd Generation Staves These were designed to provide for very high cooling capabilities. They had
increased number of cooling pipes like - additional cooling pipes in the corners, additional cooling pipes
in the refractory supporting ledge, additional serpentine pipe behind the main pipe

Figure 3.9 : Third generation staves

4th Generation Staves

Along with the 4th generation staves, concept of cast in bricks was introduced in place of conventional
refractory lining. As a result the ledge was no longer required. They used lower furnace volume and hence
more furnace volume was available. They were faster to install and underwent lower damage and hence
provided more stable inner profile.

Figure 3.10 : Fourth generation staves

Development of copper staves

Cast iron staves were suitable only for areas of low heat flux for multi campaign use. In high heat load
areas, these generally gave a life of about 6 to 12 years. Within the furnace campaign they could suffer
extensive damage. To meet cooling requirement after damage of stave, water pipes, small size cooling

33
plates etc had to be installed. To overcome these limitations, cast copper stave were tried out in Japan
early 70’s. Thyssen & MAN GHH experimented with rolled copper stave in 1979

Figure 3.11 : First rolled copper stave

Copper staves had very low wear – 3 mm in 9 years. In the same period the adjacent cast iron staves had
seen much higher wear & suffered damages. They exhibited much lower stave temperature compared to
cast iron. They did not exhibit higher heat flux. Temperature fluctuations were seen to be lower lower in
copper staves

3.3 Blast Furnace Process

BF – Feed material
Coke in BF fulfils different functions. Besides supplying heat and reductant for processing the burden into
finished products, it supports the entire burden column. It provides permeability to the burden, especially
in the region where the iron bearing material starts to soften and melts (becomes a psty mass). This region
in a BF is called cohesive zone. Being the only material to remain in solid form in the hearth, it provides
passage for flow of liquids in the hearth. It also acts as carburization agent for the pig iron.

Iron Ore is the primary source or Fe for BF. Iron ore production is processed in three forms: lump, fines
(-6.3 mm) for sinter feed and ultra fine (<150μm) for pellet feed. Lumps is the only form in which
naturally occurring iron ore is charged in BF as it is. However, it is hardly charged as found in nature
beyond 10-15 % in most large BF’s.

Some terms & definitions

Iron ore is defined as any rock, minerals or aggregates of minerals, natural or processed, from which iron
can be produced commercially. The principal ferriferous minerals occurring in iron or either singly or
severally are:
 red, brown and specular hematites, martite and magnetite
 hydrated iron oxides, including goethite, limonite and limnite
 iron carbonates, including siderate or chalybite, ankerite and other mixed carbonates
 roasted iron pyrites or pyrite cinders
34
  ferrites (e.g. calcium ferrite) occurring sometimes in natural ores, but mainly in fluxed pellets and
sinters.
 also included are manganiferous iron ore and concentrates that contain not more than 8%
manganese by mass (dry basis after heating to 105°C).
 Excluded are finely ground ferriferous minerals used for pigments, glazes, dense medium
suspension and other materials not related to iron- and steelmaking.

Natural iron ore is ores as extracted from mines and not subjected to any processes of benefication other
than sizing; such ores are also called direct shipping ores or run-of-mine ores.

Lump ore, ore lump are ores consisting of coarse particles, with a specified lower size limit in the range of
10 mm to 6.3 mm.

Sized ores are ores that have been prepared to meet specific size limits.

Fine ores, ore fines are ores consisting entirely of small particles. With specified upper size limits in the
range of 10 mm to 6.3 mm.

Processed ores are ores treated by physical or chemical processes to make them more suitable for the
subsequent production of iron and steel. Main purposes of processing include the following:
 decreasing harmful impurities such as phosphorous, arsenic or sulphur compounds
 decreasing slag-forming constituents
 raising the iron content
 improving operational factors such as the reducibility of the furnace burden

Concentrates are processed ores in which the percentage iron content has been raised.

Agglomerates are processed ores formed into coherent pieces which are substantially larger than the
original particles. The industrial processes for making agglomerates include sintering, briquetting and
pelletising.

Sinters are a type of agglomerate made from fine ores by means of forced drought combustion of an
admixed fuel. Sinter forms through adhesion between particles due to superficial melting, diffusion and
recrystallization.

Briquettes are agglomerate formed by compressing fine ores in moulds, usually employing bonding
agents.

Pellets are spherical agglomerates formed by balling fine ores, usually finer than 100 mm, with varios
additives followed sometimes by hot or cold bonding induration. Pellets may be acid, partially fluxed,
fluxed or super-fluxed, according to their acid and basic oxide contents.

Direct reduced irons are natural or processed ores that have been reduced partially, or almost completely
by thermal processes to form high grade feed for iron- and steelmaking. DRI also includes metallized
products that have been further processed by hot or cold briquetting.

Hot briquetted irons are direct reduced iron briquetted at a temperature grater than 650°C and having a
density greater than 5 g/cm3.

Cold briquetted irons are direct reduced iron briquetted at a temperature lower than 650°C and having a
density lower than 5 g/cm3

35
Degree of metallization is ratio of the content of metallic iron to the total iron content, calculated using the
following equation:
Degree of metallization = (WMFe/WFe)*100
Where,
WMfe is the metallic iron content, as a percentage by mass
WFe is the total iron content, as a percentage by mass.

Tata Steel receives its ore from Noamundi, Joda & Khanband.

To look closely at some properties of iron ore - Noamundi iron ore deposit has a maximum iron ore
content of 69% and alumina content of 7%. This has to be beneficiated at a rate of 6 million tones per
year to produce 1.4 % Al2O3 in lumps and 2.2 % Al2O3 in fines concentrate as sinter feed material. The
products of the process plant are broadly categorized in sized ore (-40+10 mm), fine (-10+0.15 mm) and
slimes (-0.15 mm). The mineralogical characterization of fine (-1.4 mm) iron ore from Noamundi Iron Ore
Washing Plant shows that it contains hematite (Fe2O3) and goethite/limonite(Fe2O3.H2O/
2Fe2O3.3H2O) as major iron bearing mineral and kaolinite (Al2 SiO5(OH)4) and gibbsite (Al(OH)3) as
major alumina bearing mineral and gangue is mostly contributed by quartz (SiO2), mica, clay, feldspar
(KAlSiO3O8, NaAlSiO3O8, CaAl2Si2O8) and pyroxene (MgSiO3).

Fig 3.12: Graph indicating world iron ore production along with steel production

Sinter is agglomerate of iron ore fines (-6.3mm). Sinter feed is the most common burden for blast
furnaces. Sinter being friable, cannot be transported far thus sinter plants are close to steel plants.

Pellets is the only method for creating a blast furnace charge from fine grained iron ores (ultrafines or
concentrate; < 150 μm). They are highly variable in their specific content, as individual steel plants
request specific characteristics and composition required to adjust BF operation. Many mining sites have
pelletising plants at the mine site or near its terminal port. Japanese steel mills have pelletising plants on-
site, but also import pellets with very specific composition. In the recent past high cost of pellet
production had caused closure of several pelletising plants. Lower iron content in ore leading to reduced
quality of sinter feed and the lower availability of quality lump ores have renewed the expectation that
pellets will begin to take market share.

36
BF – Reactions

Preheating
Zone
Ga
s
So
li ds 3Fe2O3 + CO  2 Fe3O4 +CO2

Fe3O4 + CO  3 FeO +CO2

Chemical Inactive Zone

FeO + CO  Fe +CO2
+
Unreduced FeO

of WustiteReserve Zone
Thermal
Reduction Zone
IndirectZone FeO + CO + C Fe +2CO
Indirect Reduction CO2 + C  2CO
CaCO3 CaO +CO2
MnO + C  Mn +CO
Direct Reduction P2O5 + 5C  2P +5CO
SiO2 + 2C  Si +2CO
and Melting Zone S +CaO +C  CaS +CO

Figure 3.13 : different Zones in BF

BF process can be divided into different temperature zones. Corresponding to each temperature interval
typical reactions take place.

In the tuyere region the highest temperature is observed. Due to exothermic coke combustion reaction,
temperature rises up to 2400°C or more and carbon dioxide is formed.

C + O2  CO2 - H (1)

Because of the high temperature conditions, immediately within the raceway solution loss reaction occurs
reducing carbon dioxide to carbon monoxide which is an endothermic reaction.

C + CO2  2 CO +H (2)

For all practical purposes, only the following reaction may be considered to take place at the tuyere:

2C + O2  2 CO (3)

37
At temperatures higher than approximately 1000°C, direct reduction takes place through the following
reactions:
FeO + CO  Fe + CO2 (4)
C + CO2  2 CO (3)
FeO + C + CO  Fe + 2CO (5)

Due to solution loss reaction, direct reduction is endothermic. At temperatures below 1000°C approx.,
solution loss reaction cannot take place and iron oxides are reduced as per:

FeO + CO  Fe + CO2 (6)

This indirect reduction is exothermic. Therefore the region of exothermic indirect reduction should be
large compared to endothermic direct reduction to achieve lower fuel rates. This is true for a BF due to the
endothermic nature of this reaction.

BF – Cohesive zone

Cohesive zone forms in the temperature zone of 900-1350°C. In the cohesive zone, the iron bearing
burden starts to soften and then melts. This is the region where the first liquid appears and formation of
primary slag takes place. that contains high amount of wustite (FeO) and molten iron drop downwards
through the coke bed. During this process wustite is reduced to metallic iron and a carburization takes
place. The carburization leads to a decreasing melting point and makes a tapping at lower temperatures
possible. At temperature below 900°C the iron oxides hematite (Fe2O3) and magnetite (Fe3O4) are reduced
to wustite.

BF – Top Gas or BF gas

38
Top gas or BF gas leaves the furnace with at a temperature of 150-250°C and at a pressure equal to the top
gas pressure of the furnace. Typical composition range is CO: 22 – 28 % CO, CO 2: 24 – 29%, H2 : 3-8%
& N2 40-45%. BF gas also has a huge dust content which needs to be removed before it can be put to use.
The primary cleaning system at all BF’s is a dry system where about 75% of the dust is removed. This is
typically a dust catcher. This dust is called Flue Dust and is typically recycled through sinter plants or
Rotary Hearth Furnaces.

After the dust catcher, different plants have different systems. Quite a few (especially all large BF’s) have
a wet system for faster cooling & simplicity of plant design. The clean BF gas may first be used to drive a
turbine (TRT – Top gas Recovery Turbine) to generate substantial amount of power.

Bf gas also has a calorific value of about 800 – 900 Kcal/Nm3. This calorific value is quite low compared
to coke oven gas CV of 4200 kCal/Nm3. Due to low CV, BF gas does not have a self supporting flame.
However in view of its quantity and the fact that it is available at high pressure, BF gas is the ideal fuel for
reheating furnaces & power houses in BF. It is also necessarily used for heating the stoves which heat the
cold blast for the BF.

BF – Fuel rates
Due to ecological and economical reasons the conventional blast process has changed significantly over
several decades. In the last 50 years, better burden distribution, increase in sinter and pellets quality and
quantity (up to 85-100%), high top pressure, higher hot blast temperature of 1200-1300°C has resulted in
the lowest ever fuel rates (Figure) and highest productivity. Injection of auxiliary fuels as oil, natural gas
and fine coal was started in order to further decrease the coke rate. The blast furnace process with
pulverised coal injection rate of 180-200 kg/tHM and reduction of the coke rate from 500 to 300-320
kg/tHM has been realised. Reduced fuel rates leads to a decrease in the carbon dioxide emission. Injection
of plastic, iron containing filter dust and other waste has technological, economical and environmental
advantages.

Figure 3.14 : Average fuel over the years

39
BF – Operational results

Table 3.2 : Operational features of some large BF’s around the world Jan 05

40
5 OVERVIEW OF H BLAST FURNACE
5.1 Basic Data of H Blast Furnace
BF H Basic Data
BF working volume 3230 m3
BF inner volume 3814 m3
Total Volume 4186 m3
Hearth Diameter 13 m
No. of tuyeres 34
Productivity on WV 2.21 t h m / m3
Productivity on IV 1.87 t h m / m3

Operating condition
Daily production 7,150 ton/day
Sinter in burden 70 %
Sized ore 30 %
Ferrous burden rate 1,567 Kg/THM
Fluxes 30 Kg/THM
Furnace operating top pressure 2.5 bar
Hot blast temperature at bustle main 1,200 °C
Oxygen enrichment 4%
Blast moisture 35 g/Nm3
Total Fuel rate 540 Kg/ton
Coal injection 160 Kg/ton
Nut coke rate 25 Kg/ton
Furnace coke rate 355 Kg/ton (10-18% as
center coke)
Plant availability 350 days per year
Expected hot metal analysis from BF: Si 0.5 %
S 0.04 - 0.05 %
P 0.25 %
Slag Production 272 Kg/HMT
Blast Volume (wet and enriched) 308 KNm3/h
Top gas volume wet 485 KNm3/h
Cast House
Number of tap hole 4
Angle between two tap hole, deg 75
Hot Blast Stoves
Hot blast flow rate (wet and enriched) 360,000 Nm3/h
Hot blast temperature 1,250 °C
Oxygen enrichment 6%
Moisture up to 110 g/Nm3 dry basis

41
42
Blower
Number of blowers 2
Capacity of each blower , Nm3/hr 190,000
Motor kW for each blower 23
Blast pressure. barg 5
Gas Cleaning
BF gas flow rate wet 550,000 Nm3/h
BF gas pressure 2.5 barg
Design pressure 2.75 barg
BF gas temperature 150 °C (500 °C max)
Slag Granulation
Slag production 2,430 t/day max
Max slag flow rate 8 t/min
Peak slag flow 10 t/min
Coal Injection
Number of mills One
Mill capacity, tph 60
Average injection, kg/thm 160
Peak injection , kg/thm 200
Type of injection Dense phase
BF Cooling
Number of cooling circuits 4
Type of cooling DM water , closed loop
Hearth Cooling CI staves
Shaft cooling Cu and CI stave
combination
Stockhouse
Number of bins 6C, 8S, 4O, 4A,
Storage capacity of bins Min 12 hrs for all RM
Screening Ore, Sinter, Coke
Discharge flow control Through motorized gate
Dedusting volume, Nm3/hr 450,000
Environment
Work zone dust content, mg/Nm3 2
Stack emission, mg/Nm3 30
Noise level, db 85
Shaft cooling Cu and CI stave
combination
Treated water quality after GCP-ETP - ph: 6.5-8.5
- TSS : 50 mg/l (max)
- BOD for 5 days at 20
deg: 15 mg/l (max)
- COD : 100 mg/l (max)
- Oil & grease : 5 mg/l
(max)

43
5.2 Overview of the Process

TISCO BF "H": Materials & Fuels flow diagram

(working conditions)
45975 Nm3/hr
154 Nm3/HMt

LD gas
6748 Nm3/hr db 1050
Nm3/HMt db
312857
400 Nm3/hr db
22.65 ktpy db
Nm3/HMt
8370
Oxygen for BF PCI plant Nm3/hr db
50.1 HOT STOVES+ 28
Nm3/HMt Waste Heat Nm3/HMt db
14938 Recovery system
Nm3/hr 48
t/hr
Top gas dust 160
Cold Blast (wet not enriched) BFG to
33 Hot Stoves kg/HMt
984 Nm3/HMt ktpy 458
293079 Nm3/hr 93 Nm3/HMt db
t/24hr 136373
Nm3/hr db
CastHouse dust
BF GAS
CLEANING 10 ktpy
204 0 Nm3/HMt db SYSTEM 29 t/24hr db
ktpy 0 Nm3/HMt db Hot Blast Top gas
583 1034 1536
t/24hr db Nm3/HMt Nm3/HMt db Cast House
308016 457600 DEDUSTING
Nm3/hr Nm3/hr db SYSTEM
Temperature
Top pressure
1200 °C
2.5 bar (g)

Screened BF Coke 2731 t/24hr db

382 kg/HMt db
Hot Metal
BF STOCKHOUSE

Screened Lump 3361 t/24hr db BLAST FURNACE 7150 t/24hr

ore 470 kg/HMt db WV 3243 m3 2503 ktpy
350 d/y

Screened Sinter 7843 t/24hr db

1097 kg/HMt db Granulated slag
1945 t/24hr db
272 kg/HMt
Quartzite
143 t/24hr db 72 t/24hr db 681 ktpy
20 kg/HMt db 10 kg/HMt db
Pyroxinite

5.3 Plant Layout

The index layout is shown in Drg No.061080G01002

44
6 Blast Furnace Proper & Cast House
6.1 Furnace Proper data
H BF is a free standing furnace with the following basic dimensions :
H BF – Basic Dimensions
Hearth Diameter (M) 13
Hearth Height (M) 7.2
Hearth Volume (M3) 584
Sump Height (M) 2.8
Sump Volume (M3) 372
Height : Tuyere – Taphole (M) 4.4
Bosh Height (M) 3.95
Bosh Volume (M3) 598
0
Bosh Angle (deg) 77 22’ 17”
Belly Diameter (M) 14.7
Belly Height (M) 2.1
Belly Volume (M3) 360
Stack Angle (deg) 810 24’ 47”
Stack Height (M) 17.45
Stack Volume (M3) 2052
Throat Diameter (M) 9.5
Throat Height (M) 1.6
Throat Volume (M3) 113
Total Height : Bottom Plate – Top Ring (M) 33.1
Working volume (M3) 3230
Useful Volume (M3) 3814
Total Volume (M3 ) 4186

6.2 Blast Furnace Foundation

The H Blast Furnace concrete foundation is schematically shown below :

2nd. Circular Pedestal

st
1 Circular Pedestal

RAFT

H BF Foundation details
Elevation (-) 3.550m to (-) 0.050m
Raft Size 45.3m x 28.8m x3.5m
Concrete Volume 4566 m3
Elevation (-)0.050m to (+) 2.230m
1st Pedestal Size 22.6m dia. X 2.18 m
Concrete Volume 900m3
Elevation (+) 2.230m to (+) 4.530m
2nd Pedestal Size 17.2m dia. X 2.3m
Concrete Volume 500m3

45
Pile details
H BF Pile details
Diameter of pile 1000 mm
Average depth of pile 30m
Weight of reinforcement 1.8 Ton
Total no of Piles 187 nos
Max. dia. of main reinforcement (with liner) 28mm
Max. dia. of main reinforcement (without liner) 32mm
Grade of concrete M-25
No. of rig used 13 nos

6.3 Blast Furnace tower structure

The furnace tower is subdivided into three sections namely the
lower tower,
middle tower
top tower.
Furnace tower structure will be of portal 4-column type structure and will support bustle main, pipework
for water supply and drainage, working and maintenance platforms, furnace top machine room etc.

The lower tower will be a four leg portal structure extending from concrete column top level positioned at
about 10 meters above ground to the top of bustle pipe supporting beams.

The middle tower will be a latticed structure extending from lower tower to BF top platform, with cross
shaped section columns and "I" beams. An auxiliary building for hydraulic and lubrication units necessary
to operate the B.F. top equipment and a gas analyser room will be located at the top platform. The middle
tower will support the furnace top tower along with profilometer and under burden probe

The top tower will consist of structure extending from the top platform to the bleeders platform and it
will support the runway for the outrigger hoist and the charging conveyor.

6.4 Blast Furnace Shell

The Blast Furnace shell is made from P 355 NH (1.0565) EN10028. with the following specification

Chemical composition
C-0.18 Max, Si-0.5 max, Mn-0.9 to 1.7, P-0.02 max, S-0.004 max, Al-0.02 min, Cr-0.3 max, Cu-
0.3 max, Mo-0.08 max, N-0.02 max, Nb-0.05 max, Ni-0.5 max, Ti-0.03 max, V-0.1 max

Physical properties
Yield strength - 355 N/mm2
UTS - 490 to 630 N/mm2
Elongation - 22%

46
The Total weight of shell from Ring1 –Ring20 (Bottom ring to Top cone) is nearly 996.3 tons. The table
below indicates the various rings along with the thicknesses.
Ring 1 80 mm
Ring 2 80 mm
Hearth Ring 3 80 mm
Ring 4 70 mm
Ring 5 70 mm
Tuyere Jacket Ring 6 70 mm
Bosh Ring 7 55 mm
Belly Ring 8 55 mm
Ring 9 55 mm
Ring 10 55 mm
Ring 11 55 mm
Ring 12 55 mm
Stack Ring 13 55 mm
Ring 14 55 mm
Ring 15 55 mm
Ring 16 40 mm
Throat Ring 17 40 mm
Ring 18 70 mm
Top Cone Ring 19 40 mm
Ring 20 40 mm
Drg No. 061004FB3001 attached indicates the dimensional layout of shell.

Bottom Plate : The bottom plate along with bottom cooling is shown in the attached Drg no.
061004FB3006 Rev C
The four uptakes and downcomer leading to the dust catcher is shown in Drg no. 061004G01009
Rev A
The cooling staves layout is shown in the table below :
Area Stave No. Material Qty
H1 Cast Iron 46 + 2
H2 Cast Iron 48
Hearth H3 Cast Iron 40 + 4
H4 Cast Iron 48
Tuyere Jacket T Cast Iron 48
B1 Copper 48
Bosh - Belly B2 Copper 48
S1 Copper 48
S2 Copper 48
S3 Cast Iron 48
Stack S4 Cast Iron 44
S5 Cast Iron 44
R1 Cast Iron 36 + 2
R2 Cast Iron 38
Throat R3 Cast Iron 38

Drg No. 061004G22001 shows the detailed layout of all staves.

47
 Copper
Stave

Fig 6.1 :Typical

General
Arrangement of
Cooling Staves
Installed Inside a
Furnace Shell

48
 .
Fig 6.2: Staves For Tuyere Zone
Tuyerestock

Fig 6.3 : Cardan type tuyerestock

49
50
6.5 Blast Furnace Refractory
The Distribution of BF refractory is shown in the Drg. no. 061004G11001 Rev A

6.6 Bell Less Top (BLT)

The BF top has a PW design Parralel Hopper Bell Less Top (BLT)

The BLT has the following equipment / facilities :

• Distribution Rocker and its drive along with discharge chute
• Material Hoppers – 2 nos of capacity 65 m3
• Upper & lower seal valves – 2 nos each with valve casings
• Material flow control gates
• Discharge funnel, expansion bellows and distribution chute
• Gear box assembly – Reinforced type with water cooling
• Each hopper has hydraulically operated equalizing and relief valves
• Equalizing system for optimizing weighing control

BLT – Equipment
The Tilting rocker receives the material coming from the stock house
Tilting Rocker (TR) by conveyor belt and has a tilting movement in order to transfer this
material into the hoppers 1 or 2.
Upper Seal Valves These valves are installed on the upper part of each hopper with the
(USV1, USV2) function of performing the sealing of the material entrance during the
discharge into the hoppers.
These two hoppers have a storage function for the material to be
Material Hoppers (H1,
discharged into the blast furnace. Each Material Hopper is equipped
H2)
with 3 load beams.
Lower Material Gate The Lower Material Gates are installed each in a casing, one gate for
(LMG1, LMG2) each hopper. The Lower Material Gates control the material flow
coming out of the material hopper
Lower Seal Valves There are also two lower seal valves, one for each material hopper,
(LSV1, LSV2) each also installed in a valve casing. These valves permit the filling of
the material hoppers keeping the blast furnace closed.
This valve is installed below the centring device and over the gearbox,
Goggle Valve (GV)
for maintenance purposes, to insulate the equipment over this level.
Distribution Chute The distribution of the material into the blast furnace is performed by
(DC) this tilting and rotation device
Relief Valves (RV1, The valves permit the depressurizing to the atmosphere of the material
RV2) hopper
Primary Equalizing These valves permit the pressurizing of the material hopper with semi-
Valves (EV1, EV2) clean
Secondary Equalising These valves permit the complementary pressurising of the material
Valves (SEV1, SEV2) hopper with nitrogen

BLT Operation
The BLT Operation data :
• Coke rate max flow – 0.8 m3 / s & min flow – 0.2 m3 / s
• Normal Top Temp – 150 0C to 250 0C
• High Top Temp – 450 0C ( duration 15 min, 20 times per year )
Max Top Temp – 900 0C ( duration 5 - 10 min, 1 time per year )

51
Fig 6.4 A : H BF BLT - schematic
Parallel Hopper BLT

52
Fig 6.4 B : H BF BLT - schemati

Belt conveyor

Distribution rocker

Upper seal valve

Weigh hoppers

Support for load bars

Valve casing

Discharge funnel
Bellow arrangement
Goggle valve
Chute transmission gear box

Rotating chute

53
Filling hoppers
The burden brought up by conveyor belt is charged via the tilting rocker into one of material hoppers.
Conditions
o hopper empty
o tilting rocker horizontal position
o equalising valves closed
o relief valve closed
o hopper pressurized
o upper seal valve closed
o lower seal valve closed
o material gate closed
Sequence start
o Batch head on point C of conveyor belt
o open relief valve
o open upper seal valve
o tare hopper
o rocker tilting towards hopper
o hopper tarred (measured net weight of the hopper reset to 0)
o Batch head reaches point B of conveyor belt
o hopper filling
o filling finished
o compared net weight of the hopper with the expected weight from the stock house
o tilting rocker to horizontal position
o close relief valve
o close upper seal valve
o open equalising valve
o close equalising valve
o open secondary equalising valve
Discharge (may be started during filling of other hopper)
Conditions
o hopper filled and pressurised P hopper (PBF - 0,15 bar)
o stockrod level gauge in garage position
o BF ready for charging
o choice of desired outflow rate according to the discharge parameters
Sequence start
o open lower seal valve
o open lower material gate according to the desired
o outflow rate. Start timer to check out flow rate.
o Hopper empty (zero flow rate + empty signal from weighing system).
o Compare real outflow rate with precalculated outflow rate
o open material gate completely
o close secondary equalizing valve
o close lower material gate
o close lower seal valve

BLT Chute Tilting and Positioning

The chute tilting movement is divided into 11 positions where the position 11 is on the wall and the
position 1 is in the centre of the BF

54
Chute Dimantling
During normal operation chute can be taken only upto 53,5°. To dismantle the chute, it must be
positioned in front of dismantling door & in local mode taken to 2 other upper limits 70° and72° by local
control box for dismantling.

BLT Chute Rotation

Is for rotation of chute for distribution of material in the furnace
The position of the chute is given by two encoders (one operating and one standby)and one limit switch.
The encoder is provided for initiating the material discharge into the furnace and for sector charging (low
speed only is used for sector charging).
The chute rotation direction (left or right) can be selected and will be changed based on the number of
charges dumped in to the furnace, in order to guarantee an equal wear of the chute.
Normally the chute rotation will not be stopped in the automatic control mode (to reduce mechanical
stress on the gearbox) and is rotating at high speed (1 revolution = 7,5 seconds). However, if the upper or
lower limit is reached it will be stopped and an alarm will be given.

Gear Box Cooling

The bell less top is cooled by a closed loop water circuit. Two pumps are installed (1 in operation, 1 in
stand-by). The water is pumped out of a closed water reservoir to the upper trough inside the chute
transmission gear. From there, the water flows by gravity through the serpentines to the lower trough in
the chute transmission gear box.
NITROGEN COOLING
Nitrogen will be permanently injected in the chute transmission gear (approx. 200 Nm3/h) to create a
slight overpressure to avoid dust entering in it.

Fig 6.5 : Water distribution in the chute transmission gear

55
The water, entering the gearbox is collected in the upper, rotating trough of the bell-less top .From there,
the water flows by gravity through the serpentines to the lower trough. In parallel to these serpentines, two
overflow pipes between upper trough and lower trough are installed. Water pipe routing from chute
transmission gear to the water reservoir has 4 outlets, each of DN 50 mm, are installed at the bell-less top.
The pipe routing to the water reservoir is to place with a slope of 2 % min. A butterfly valve with limit
switches DN 100 is installed for the purpose of isolating of the water reservoir during eventual
maintenance works. A connection from the water pipe to the pressure equalizing line between water
reservoir and bell-less top is installed with a butterfly valve DN 100 to avoid a siphon effect and herewith
pulsations of the water level in the trough. The connection to the equalizing line has to be higher than
lower trough.

If the temperature difference of the inlet water and the outlet water is higher than 5° C, an alarm will be
given. In this case, the water flow, respectively the B.F. top gas temperature must be checked.
When the water temperature exceeds 55° C an alarm is given. The operator has to check the function of
the cooling circuit.

BLT Cooling System

Pump station
- 1 pump in operation (Pump capacity: Q = 25 m³/h)
- 1 pump as standby
Description and working of the hydrocyclone
a) Centrifugal separation
The performance of a hydrocyclone is determined by the difference in weight (specific gravity) between
the solids and the liquid involved. The water flows upon tangential entry into the acceptance chamber, the
liquid/solids are drawn through internal tangential slots and accelerated into the reduced diameter
separation cylinder. The solids heavier than the carrying liquid are centrifugally spiralled down the
perimeter of the separation cylinder, past the deflector stool and allowed to accumulate in the separator’s
collection chamber.
b) Sludge flushing
The sludge flushing is controlled on time base. The interval between two flushings is 8
hours. The flush valve will be opened and remains open for 30 seconds (approx. 300 l).
The collected particles in the sludge receptacle are washed out through the flush valve and
flush pipe
Heat Exchanger
1. Water/water heat exchanger is installed.

BLT Steam Heating

Condensation water vapour from the furnace onto the bell-less top hopper seal valve seats (upper and
lower) can cause adherence of dust and dirt leading to fouling and poor sealing. This will be prevented by
steam heating of the valve seats ,fig below shows the arrangement.
There are four identical circuits installed for upper and lower seal valve seats. The seat temperature will be
set in the range of 90 – 105°C. The temperature will be controlled by opening the automatic shut off
valves according to the actual seal valve seat temperature measured by the resistance thermometers
Whenever the temperature transmitters reach 130°C, an alarm is issued in order to warn the operator to
check the functioning of the automatic shut off valves.
Whenever the temperature transmitter downstream the pressure control valve reaches 150°C, an alarm is
issued in order to warn the operator to check the functioning of the pressure control valve and to prevent
damage to the seal valve seals.
The created water due to condensation of the steam will be relieved by the float traps.

BLT Greasing System

56
B.L.T. greasing & cooling system is the most vital part of B.L.T. as any problem in the greasing system
for gear box ( cycle one) beyond 30 minutes automatically stops the charging in the furnace.
The system consists of two different greasing cycles; subdivided into two separate loops.
Cycle I : every 45 minutes (chute transmission and planetary gear)
Cycle II : every 8 hours (lower seal valves, lower material gates, upper seal valves, distribution
rocker, conveyor belt, equalizing valves, relief valve.)
Greasing System Consists of :
1. Grease reservoir.
2. Grease Pumps ( 1 running + 1 standby).
3. Electric operated change over valve
These 4/2-way changeover valves are operated by electric motors for the
(i) Fast cycle (minutes),
(ii) Slow cycle (hours).
4. Electric operated 4/2-way change over valve for selection of A or B line of slow/fast cycle.
5. Grease metering devices-The metering devices are provided with metering screws for adjustable
grease output and indicator pins. The metering screws limit the stroke of the dispensing piston. In
B.L.T. Gear box the piston position of metering devices are detected by proximity switches .Based
on these position detection signal goes to control room indicating the points which are being
lubricated.
6. End of line Pressure Switches- The end-of-line pressure switches for slow & fast cycle
respectively are mounted at the end of the main lines (A-line and B-line) of the two-line system.

6.7 Bleeder
H BF has 4 nos of bleeding arrangement
o 1 no. semi clean bleeder ND Hydraulic
o 3 nos crude gas bleeder ND 630 Hydraulic

Layout of Bleeders at H BF top is as shown in DrgNo. 061004G01009 Rev A (already attched)

Fig 6.6 : PW design bleeder

Closed position Open position

57
6.7 CAST HOUSE
Hotmetal is tapped from Blast Furnace in the Cast house & handled Liquid Metal Handling & Slag
Handling System:

Cast House Facilities / Equipment

o 2 Symmetrical cast houses with flat floors
o Runners sunk in the floor with removable covers
o Provision of splash covers on main iron trough
o Ramp from ground floor to cast house
o Ramp from cast floor to tuyere platform
o Crane for each cast house for repair and servicing work
o 4 sets of hydraulic clay guns (operable from control room , local & wireless)
o 4 sets of hydraulic tap hole drills – from control room & wireless.
o Hydraulic operated tilting runners
o Double hydraulic system for 4 sets of cast house machines
o Display of key parameters in Cast house control room

Photo of a similar plant

Cast house Building

 Bottom hinged frame construction

 Top of casting platform 9,800 mm approx
 Column space 10,000 and 12,000 mm approx
58
  Frame span 27.45 m approx
 Hall length 73 m approx
 Crane runway level 26,600 mm approx
 Slope of the roof 15 %
Cast House will be designed to permit entry of torpedo cars having the following dimensions:
Height: 4.5 m above the rail top
Length: 23.5 m coupler to coupler
Width: 3.7 m
The cast house floor is made of Steel structure beams and concrete. Under the platform construction
& in the areas of the rail tracks, heat protection plates are provided.

Casting Data
No. of cast Houses 2, symmetrical
No. of Iron Notches 4
Angle between tapholes 75 deg
No of castings per day 12 (normal)
Tapping speed 3.2 tons / min (avg)
Slag flow rate 1.6 tons / min (avg)
Hot metal per cast 595 tons ( avg )
Slag per cast 165–183 tons ( avg )

Iron and slag runners

 Provided for a total of 4 iron notches.

59
 All runners for iron, slag and skimmer remaining iron will be executed in concrete.
 Iron runners slope: 4%
 Slag runners slope: 8%
 Metallic spouts will be provided for iron, slag runners and drain iron runners.
 Initial runner preheating arrangement is provided

60
Taphole machines
Each of the four tapholes are equipped with :
o a taphole opener,
o a claygun machines and
o a runner cover manipulator.
The hydraulic power for the above is provided through two nos of pump stations interconnected in order
to have more flexibility of the equipment.
The system operates at
o Design pressure 315 bar
o Operating Pressure 200/290bar
o Main pump flow rate 90/160l/min (200/290bar)
The hydraulic system (2 nos) comprises
o Oil tank (carbon steel) 2000ltrs
o pilot oil pump 100l/min (50bar)
o 1 circulation pump 100l/min (10 bar)
o 1 filling pump 20 l/min
o 1 accumulator station 2 x 120l oil with 24 N2 bottles
o 2 valve desks.

Claygun
Claygun Technical Data
No. of clayguns 4
Type of machine Hydraulic
Swiveling, Pressing,
Driving mode
Plugging
Maximum jib arm slewing angle 114°
Maximum clay gun slewing angle 40°
Useful clay barrel volume 210 lit
Cylinder I.D., mm 400
Barrel I.D., mm 480
Nozzle inner diameter, mm 150
Hydraulic Pressure, kg/cm2 280
Pushing Force, tons 450
Mud Pressure kg/cm2 200
Pressure on clay mass (max.) 200
Paking Force, tons 35
Clay injection rate, lit/sec 35
Taphole Angle 8-12 deg (normal 10)
Slewing time 10-15 sec
Max Ramming cylinder pressure 280 bar
Height of the machine 1550 mm
Weight of the clay gun unit 6040 kg
Total weight of the machine 21000 kg

Hydraulic Operated Claygun is provided for closing tapping having following mode of operation:-
1. Swivelling forward/ backward for positioning or withdrawing mudgun from taphole.
2. Plugging-for pushing clay in the taphole at desired pressure.
61
Start up conditions for mudgun:
1. The machine is preselected on the control desk by the operator, and the hydraulic power station
will start up with 290 bar pressure as set point.
2. Taphole drill in retracted position.
3. Cover manipulator in retracted position.
4. Claygun slewing selected.

Photo of a similar mudgun

CLAY INJECTION CYCLE

MUD GUN CLAY PUSHING BARREL(with serpentine water cooling arrangement)

62
Taphole Drilling Machine

All four tapholes are provided with individual TMT make Hydraulic Drilling Machines. The basic data for
these drilling machines is provided below :
Drill machine Technical Data
No. of Drill machines 4
Type of machine Hydraulic
Taphole opening Technique Conventional soaking bar
Stroke length 4.5 m
Tapping Depth 3500mm approx
Drill angle 8°-12° (normal 10°)
Drill bit diameter 35-80mm
Drill bar diameter 38mm
Soaking bar diameter 40-70mm
Drill bit air flushing pressure 5 bar
Drill bit air flushing flow 3,5 Nm³/min
Drill bit water flushing flow 4 lit/min
Drill bit water flushing pressure 50 bar
Drilling speed (approx.) 0.15 m/s
Hydraulic Drill Hammer
Hydraulic input force Forward 50 KW
Backward 45 KW
Oil consumption Forward 155 lpm
backward 140 lpm
Operating Pressure Forward 200 bar
Backward 200 bar
Rotator
Hydraulic input force
Maximum speed 460 rpm
Maximum torque (at 460 lpm) 660 N-m
Oil consumption 120 lpm
Operating Pressure 200 bar
Feed Motor
Retraction speed (no drilling) Max 1 m/s
Oil consumption 130 lpm
Operating Pressure 200 bar
Feeding Power Max 4000 kg
Slewing
Slewing time Approx 25 sec
Weight of roller carriage 4200 kgs
Weight of hydraulic taphole drill Approx 15 tons

The taphole drill will be equipped with modern hydraulic drill technique, such as:
o Guide channel
o Hydraulic front centre tongs
o Hydraulic rotator, up to 460 rpm
o Hydraulic forward and backward hammer
o Hydraulic feed motor, up to 4,000 kg feed force
o Electronic measuring device for travel feed and taphole length
o Hydraulic drill hammer

63
 o Control device for
 Feed force
 Rotator speed
 Percussion capacity via switches at the radio remote control / desk
o Automatic drilling process control system
o Control desk located in the keeper's control room, wireless control
o Full hydraulic drive system
o Hydraulic motor/cylinder for swivelling the boom as well as lifting the drill mast
o Hydraulic drive for drill hammer, rotator, feed motor, front tongs and center support

The Taphole Drill would has the following motions :

o Swivelling, lifting and tilting - Hydraulic
o Drill hammer, rotation and feed - Hydraulic
o Drill rod centring , simultaneous movement - Hydraulic
of both tongs arms.
o Drill Hammer Forward Backward - Hydraulic

Start up conditions for Drilling Machine:

o The machine is preselected on the control desk by the operator, and the
hydraulic power station will start up with 200 bar pressure as set point.
o Mud Gun drill in retracted position.
o Cover manipulator in retracted position.
o Drill m/c selected.

Drilling Method

64
These mud qualities allows the adoption of a tapping rate of 3.2 t/min and a tapping duration of 180 min.
about; its binding time is compatible with casting interval of 30 min. Therefore the following specific
features have been considered dealing with the casting process:
o Average casting speed: 3.2 H Mt /min.
o Average casting duration: 180 min.
o Average trough interval (time between closing and drilling of a taphole), also
considering a sufficient time to carry out the normal cast house work for casting operation: 40 min.
minimum.

Cover Manipulator
Cover Manipulator is used to place trough covers over the main trough as protective device to protect
persons working in the cast house from HM splashes coming out of taphole. This device is used for
placing the first trough cover over the trough as it is not in the reach of cast house crane. Rest other covers
are placed by cast house crane.

Technical details of manipulator are as follows:

Motions Lifting and slewing
Drive Hydraulic
Lifting capacity, t 20
Slewing angle, deg 115
Lifting height, mm 500
Lifting time, sec 15
Slewing time, sec 30
Overall weight, t 35
Distance center of rotation to runner, m 5
Hydraulic pressure, bar 290
Admitted flow, lt/min 20

OPERATION OF SPLASH COVER MANIPULATOR

Pre conditions :
1. Cover manipulator has to be pre-selected.
2. Drilling machine is in resting position.
3. Mud Gun is in resting position.
4. Cover manipulator in resting position

OPERATION
Once the above condition are met the operator can give the command of lifting the cover. On reaching end
position the operator can give the command of rotating the cover. On reaching end position the operator
can give the command of lowering the cover The movement will be continued until the lowering
command is given, or the lower position is reached.
The operator has to visual check the actual position of splash cover at every command.

65
Tilting Runner

Hot Metal tapped from the Blast Furnace in Cast House through four main hot metal runner will be go to
tilting runners after slag is separated out . Hot Metal will be poured in Torpedo Laddles placed in the three
Rail lines layed below each Cast House with the help of respective tilting runners.
Pneumatic Operated Tilting Runners will select the rail line in which hot metal has to be poured.
Hand operated wheel is provided for emergency operation.

 BF hot metal casting rate approx. 6-8 t/min

 Number of tilting runners 4
 Length of tilting runners 5,600 mm
 Tilting angle in pouring position approx. 10°
 Tilting angle in emptying position approx. 20°
 1 tilting runner body of welded construction, fabricated from 20 mm, 25 mm and 70 mm thick
plates.

Crane and Hoist

Casthouse crane: Each casthouse will be equipped with one crane 35/10 t capacity. By means of the
casthouse cranes, the tilting runner, the cover for iron and slag runner will be positioned. And this crane
will be used for regular operation and maintenance work in cast house.
For handling mudgun, series of monorails are provided

Crane schedule for blast furnace

Description of crane Installation area Capacity (Tons)
Outrigger electric crane BF proper 35
Double girder EOT crane PCI building 35
Double girder EOT crane Blower house 60/15
Double girder EOT crane Cast House 35/10
Single girder underslung 5
electric crane TRT
Single girder underslung 7
electric crane SH screen handling
Single girder underslung 5
electric crane SH top floor service
Single girder underslung PCI building (above 3

66
electric crane bag filter)
Single girder underslung Main Pump house 5
electric crane (Ground floor)
Single girder underslung Main pump house (first 3
HOT electric crane floor)
Single girder underslung 3
HOT electric crane GCP pump house

67
 6 Stockhouse
6.1 Process Description & Stockhouse Layout
Inputs to the Stockhouse
The stock house is fed by belt conveyors at the top of the stock house:
o 1 for coke which will receive coke from Haldia coke storage yard
o 1 for sinter which will receive sinter from SP#4 or SP#3
o 1 for additives/ lump ore which will receive ore/additives from RM yard

Stockhouse Layout
The coke ,sinter and ore bins of “H” BF are laid in two rows on both sides of the main charging belt
(MB1), The sinter , ore and coke are screened under the bin while additives are not.

The layout of the Stockhouse and charging system is shown in Drg No.061002G01001 revE and the
cross section including the incoming belts are shown in the Drg No. 061002G01003 Rev B (both
attached)

Process Description
The coke supplying system includes 6 coke bins under which gates, electric vibrating feeders, linear
motion vibrating screens and weigh hoppers etc. are installed. The coke will be received from storage yard
and fed to these bins through a rotating conveyor installed at the top of bins. Out of 6 bins two bins are
dedicated to center coke charging which will be installed with +60 mm screen below to separate +60 mm
coke. Rest 4 bins are for BF coke which will separate +34 mm coke. There is at least 3 or 4 screens
aforesaid working at the same time to separate the on size coke (≥34mm) which will be discharged to the
main belt and then sent to the BF top. The screened fine coke (<34mm) will be sent to the fine coke screen
at the top of coke breeze buncker which will separate + 8 mm coke. This coke will be send back to another
screen on top of Nut coke bin which will separate + 34 mm and – 34 mm coke. – 15mm coke will be fed
to nut coke bin and +15 mm coke will be fed to BF coke bin. The screened nut coke (8~34mm) will is
discharged to the main belt through the nut coke weighing hopper, mixed with ore and transport to the BF
top. Coke breeze (<8mm) is stored in the coke breeze bunckers ( 2 numbers) and periodically sent to
proportioning bin of RMBB N through conveyor. This coke breeze buncker will have emergency gate for
loading material on truck.

The sinter supplying system includes 8 sinter bins, under which the gate, electric vibrating feeders , linear
motion vibrating screens and weigh hoppers etc are installed under the sinter bins. The sinter is received
from SP# 4 and SP#3 at the top of bins and fed to the respective bin through series of shuttle conveyors
There are at least 4 or 5 screens working at the same time for sinter depending upon the mode of charging
to separate + 5 mm size sinter. The screened sinter is put into a weighing hopper (common for two bins)
and then discharge to the main conveyor through motorized gates. Under size sinter goes to another screen
installed on the top of Sinter fines buncker where it segregate + 3 – 5 mm sinter and -3 mm sinter. +3 – 5
mm sinter sent back to small sinter bin in stock house while under size will go to Sinter fines bin ( 2
numbers) and periodically sent to proportioning bin of RMBB N through conveyor. This sinter fines
buncker will have emergency gate for loading material on truck.

68
The ore supplying system includes 4 ore bins, under which the gate, electric vibrating feeders, linear
motion vibrating screens and weigh hoppers etc are installed under the ore bins. The ore is received from
yard at the top of bins and fed to the respective bins through series of shuttle conveyors The ore is
screened before sending it to Blast furnace. As the moisture level of ore is higher which causes clogging
of screen mats opening, special designed flip flow screen is used for ore screening. These screens works
on dual vibration principle and achives high acceleration necessary for effective screening by dynamically
tensioning and relaxing the flexible screen mats. Under size ore goes go to ore fines bin (1 number) and
periodically sent to proportioning bin of RMBB N through conveyor. This ore fines buncker will have
emergency gate for loading material on truck.

Additives are planned to receive from ore incoming conveyor for which screening is not necessary before
charging to blast furnace. Additives , nut coke and small sinter are fed from weigh hopper to main
charging conveyor by feeders.

2000 mm steel cable carcass conveyor (MB1 & MB2, main charging conveyors) are installed in series to
carry raw material batches to Blast furnace top. One scoop type sampler is installed at MB1 conveyor for
sampling of coke, ore and sinter.

One magnetic separator cross belt type capable to remove tramp iron 50 ¸ 250 mm and discharging to the
side of conveyor belt MB1 (see only for reference picture 1). Useful height of belt conveyor trough is
approximately 550 mm.

Design parameters
The stock house is designed with screening facilities for coke, sinter and ore and suitable batching and
weighing facilities with a minimum of 30% force filling factor over 7,850 t/d hot metal production
considering 70 % sinter in burden.

The following percentage of fines in the raw material for the designing of equipment and bunkers.
Sinter- 20%
Coke- 12%
Ore- 10%
Material Max effective storage Number of Storage
capacity , m3 bins capacity, hrs
Center coke 550 2 12 hrs
BF coke 550 4
Sinter 550 8 15
Ore 500 4 16
Nut Coke 300 1
Small Sinter 300 1
Additives 300 3 24
DRI 300 1
Coke fines 300 2 24
Sinter Fines 280 2 24
Ore fines 170 1 24
All bins and hoppers are provided with wear protection lining, shut-off and/or feed control gate at the
discharge end.

69
Different charging modes
In the following table, for these six (6) typical cases, are shown the force filling capability and number of
weighing hopper used.

Stockhouse Equipment

Circuit Equipment Sequence of operation Qty Capacity

Screens OS91,OS92,OS81,OS82 4 95 tph

Shuttle conveyors O/AC1, O/AC2, O/AC3 3 1500 tph
Ore bins OB81,OB91,OB82,OB92 4 500 m3
Additive bins AB101,AB103,AB102, 3 300 m3
DRI bins DRIB1 1 300 m3
Ore feeders OF91,OF92,OF81,OF82 4 99 tph
AF101,AF102,AF103 3
Additive feeders AF104,AF105 2 65 tph
Ore / AF106 1 150 tph
additives DRIF111 1 65 tph
DRI feeders
DRIF112 1 300 tph
Ore fines feeders OF93,OF94,OF83,OF84 4 30 tph
OWHG91, OWHG92,
Ore weigh hoppers 4 25 m3
OWHG81, OWHG82
Additives weigh
AWH101,AWH102,AWH103 3 6 m3
hoppers
DRI weigh hoppers DRIWH111 1 6 m3
OFC1/OFC2 2 25 tph
Fines conveyors
OFC3,OFC4,OFC5 3 50 tph
Sinter SS11,SS12,SS21,SS22,SS31,S
Screens 8 109 tph
S32,SS41,SS42
Shuttle conveyors SC1, SC2, SC3 3 1000 tph

70
 SB11,SB12,SB21,SB22,SB31,
Sinter bins 8 550 m3
SB32,SB41,SB42
Small sinter bin SB51 1 300 m3
SF11,SF12,SF21,SF22,SF31,S
Sinter feeders 8 121 tph
F32,SF41,SF42
SF13,SF14,SF23,SF24,SF33,S
Sinter fines feeders 8 30 tph
F33,SF41,SF44
Sinter weigh
SWH1, SWH2, SWH3, SWH4 4 45 m3
hoppers
SFC1/SFC2,SFC3,SFC4,SFC5 5 213 tph
Fines conveyors
SFC6,SFC7 2 71 tph
Center coke screens CcS61, CcS62 2 77 tph
Surface coke
CS41,CS42,CS51,CS52 4 77 tph
screens
Coke fines screen CFS1 1 145 tph
Nut coke screen CFS2 1 110 tph
Rotating conveyor CRC1 1 450 tph
Center coke bins CcB62,CcB62 2 550 m3

Surface coke bins CB41,CB42,CB51,CB52 4 550 m3

Nut coke bin NCB71 2 300 m3

Coke
Cf41,CF42,CF51,CF52,CcF61,
Coke feeders 6 85 tph
CcF62
Nut coke feeders NCF71, NCF72 2 150 tph
CWHG41,CWHG42,CWHG5
Coke weigh hoppers 1,CWHG52,CcWHG61,CcWH 6 25 m3
G62
Nut coke weigh
NCWH71 1 6 m3
hoppers
CFC1/CFC2 2 80 tph
Fines conveyors CFC3,CFC4,CFC5,CFC6 4 160 tph
CFC7 1 120 tph

Screens details
Material to be Coke Coke Coke Ore
Coke Sinter
screened C N F
Quantity 4 2 1 1 8 4
Operative capacity t/h 77 77 110 145 109 95
Design capacity t/h 85 85 120 160 121 105
2.2-
Bulk density t/m³ 0.55 0.55 0.6 0.6 1.7
2.4
Angle of repose 38° 38° 40° 40° 38° 38°
Screening efficiency 90
90 90 90 90 90
min %
Inclination 2° ÷ 5° 2° ÷ 5° 2° ÷ 5° 2° ÷ 5° 2° ÷ 5° 2° ÷ 5°

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 Size mm W ~ 1800 1800 2000 2000 1800 2000
Size mm L ~ 5000 5000 5000 5000 5000 5300

Feeder Details

Conveyor Details: refer to attached Drg No. 061002G2201 _ A

Stock house de-dusting

To control of dusty emissions , the dedusting plant will be designed to suck and clean the dusty air arising from bins,
belt conveyor transfer points, vibrating feeders, vibroscreens, weighing hoppers and all other dust generating points. The
area covered by the system extends from the discharging points of the belt conveyors that feed the stockhouse to the
feeding points of main charging conveyor of blast furnace including the extraction and storage bins of fines. Dusty air
collected from the several suction hoods will reach, through a duct network, the bag filter, the I.D. fan (The total suction
flow rate is 450,000 m3/h) and it will be discharged to the atmosphere by means of a stack..
Suction network
Each dust source is equipped with a suction hood, shaped in order to ensure that flow rate is distributed all over the
dust generating area and no escape of dust may happen
Butterfly type valves are foreseen, to suck only needed flow rate and don't waste energy; not every source is
equipped with a valve: according to the way of operate of the equipments, more than one source can be controlled by
only one valve. The valve is operated by means of an oversized pneumatic cylinder, completely enclosed; this is done to
reach very reliable operation and low maintenance.

Ductwork is designed according to the following guidelines:

· selection of proper flow velocity (14-18 m/s) in order to prevent dust deposition on one side and duct erosion from
the other side;
· wall thickness: 3-8 mm according to size
· use of reinforcements to withstand erosion in the points that may be affected by such a trouble (bends and branch
connections, with additional external plate 8 mm thk)

72
 · provision of ports, manholes, flanged pieces in order to allow duct inspection and cleaning, eventually
Bag filter
The technical features of the bag filter are listed under item Technical data.
The filter is a pulsejet type, cleaned by compressed air pulses. Both online and offline cleaning is available. The
filter consists of a casing, made by carbon steel plates split in a number of cells. Each cell is completely independent from
the other; each cell is equipped with a manual valve on dirty side and an automatic poppet valve on the clean side; each
cell has a separate hopper. Each cell is complete with compressed air distribution system with buffer tanks, nozzles
ramps, venturi tubes for each bag. To ensure a proper flow distribution and to separate coarse dust in the hopper to
prevent bag damages, internal baffles are foreseen at the inlet of each cell. The filter is complete with a compressed air
tank with an adequate volume and a compressed air dryer. The bag houses will be fed by the compressed air produced in
the centralized compressor station.
On top of the filter an electric hoist is provided and a rain roof.
Technical data:
· flow rate 450,000 m3/h
· operating temperature 30 °C
· inlet dust load 15g/Nm3
· outlet dust load (guaranteed) 10 mg/Nm3
· filtering surface 4,500 m²
· bag material polyester needle felt 550 g/m2
· n° of cells (minimum) 6, placed on one row only
· estimated compressed air consumption 650 Nm3/h
· compressed air pressure 6 barg
· plate thk of casing and hoppers 5 mm

Dust evacuation
Dust collected by the filter is discharged to a longitudinal chain conveyor located below hoppers bottom. The
conveyor feeds a dense phase pneumatic conveying system that feeds a silo. The pneumatic conveying pipelines are
provided with suitable liner. Silo venting will be performed by means of the main bag filter. The dust silo is equipped
with a telescopic dust discharge device, complete with a suction pipe to prevent dust spillage to the atmosphere. The
suction pipe is connected to the inlet side of filter. This discharging system is designed to fit a closed tank or a truck with
a circular opening; it is placed at an elevation of 4500 mm above ground level.
Main data are:
· dust discharge capacity 6 t/h
· dust buffer capacity 24 h, 80 m3
· dust bulk density 1,200 kg/m3
Exhaust fans
Clean air coming from filter is moved by two centrifugal fans.
Main data are (each fan):
· flow rate 225,000 m3/h
· head 55 mbar

73
· operating temperature 30 °C
· power consumption 430 kW
· rotating speed 990 rpm
· motor 500 kW, 6 poles, MV

74
7 Gas Cleaning Plant

7.1 Introduction
High efficiency Gas Cleaning Systems are vital for the reliable operation and long campaign life of high
temperature hot blast systems and steam generation facilities. The Gas Cleaning systems (Flow diagram
shown in Figure 1) are designed to the highest levels of cleaning efficiency, safety and reliability and
provide the best possible environmental protection.

Main units of GCP

1. Dust catcher
2. Scrubber (Including primary & AGS)
3. Demister
4. Water system
5. Hydraulic system
6. Gas network

Figure 7.1: BF Gas Main Flow Diagram

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7.2 Dust Catcher
Dust Catcher – Technical data
B.F. gas max wet flow rate 550,000 Nm³/h
150 °C normal
B.F. gas temperature
500 °C max for short time
B.F. gas pressure 2.5 bar g max
Design pressure 2.75 bar g
Dust catcher free diameter 11.2 m
Funnel diameter 6.1 m
Inlet diameter 2.6 m
15 ÷ 20 g/Nm³ peak
Gas dust content at d.c inlet
10 g/Nm³ normal
Gas dust content at d.c outlet 5 g/Nm³
Material Fe 510 C and D
Connection duct to Venturi scrubber 2600 mm OD

The crude gas (volume 550 kNm3/h, pressure 2.5 bar, temperature 200° C, dust content 10 g/Nm3) from
the top cone of the blast furnace comes to dust catcher through down comer (ф 3000x18mm,material
I.S.-2002-2)as shown in Figure 2. The inner side of the down comer has alumina bricks.

Down comer

Figure 7.2
The crude gas in the dust catcher enters through diffuser cone. The velocity decreases as area increases,
as a result nearly half of the dust fall in the dust catcher (dust content reduces up to 5 g/Nm3).

76
 Prior the dust discharge from dust catcher, the equalizing vessel is pressurized by means of nitrogen,
than the inlet rotating disc valve located on the equalizing vessel inlet is open. The dust by gravity falls
inside the equalizing vessel. The filling of the equalizing vessel is controlled by the load cell installed
under the equalizing vessel itself as shown in Figure 3.

To discharge

Figure 7.3

Then the inlet valve closes and the depressurization of the equalizing vessel start. Once the pressure
reaches the atmospheric, the rotating disc valve located downstream the equalizing vessel opens and by
gravity the dust falls inside the pug mill.

From the pug mill the dust is discharged directly onto a truck. Dust evacuation will be carried out once a
shift (3 times a day) through pay loader-trucks route

Main advantages of the system are:

o No gas leakages in the area

o Reduction of wear in comparison with the differential pressure dust discharge
o No dust pollution in the area due to the fact that efficiency of moisturizing process of dust
inside the pug mill is greatly enhanced by residence time increase
o Fully automatic system (only one start command from control room is required)
o Daily reports available (timing, dust weight discharged)
o Reduction of maintenance
Pug Mill

77
 The pug mill is situated at the bottom part of dust catcher.Dust falls inside the pug mill after passing
through equalizing tank.

The pug mill standard capacity is 75 t/h.It consists of housing of welded construction. Distance between
inlet and outlet nozzles is 4,000 mm, with internal transportation and mixing screw with the blades partly
hard-faced, Water injection device, driver assembly including gearbox, couplings and drive motor.

In pug mill the agitating impeller (60 to 100rpm) mix the dust uniformly and rapidly, water will be
sprayed from the sides (upper part) of the body through the pump. The dust would be mixed with
sprayed water, and loaded on the trucks through the chute on the lower part of the body

Pug Mill – specification

Type Double axis and impeller type
Capacity 75 t/h
Speed reduction motor 1 nos.
Motor type self ventilated & squirrel cage
Suitable to work in a dusty environment at 55°C
Power source 50 Hz, 415 V

7.3 Annular Gap Scrubber

Scrubber – Technical data

Dust content at Venturi scrubber inlet (raw gas) 5 - 10 g/Nm3
Dust content at first stage outlet (semi clean gas) < 100 mg/Nm3
Dust content at Venturi scrubber outlet < 5 mg/Nm3
Mist content at Venturi scrubber outlet < 5 g/Nm3
Diameter/height (approx) D = 5,200 mm/H = 28 m
Total pressure drop 250 - 2400 mbar
Pressure drop at quencher stage 50 - 200 mbar
Pressure drop at second stage 200 - 2,200 mbar
B.F. gas outlet pressure 150 - 80 mbar
B.F. gas outlet temperature 45 - 55 °C

After passing the dust catcher the crude gas enters the wet scrubber (material SA 516 Gr 60/70) from the
top (Figure 4) through connecting pipe DN 2600.The pipe is made of CorTen steel with no internal
refractory lining, good resistance to temperature and corrosion, no expansion joint (duct and scrubber are
designed to withstand thermal expansion forces and displacements).

78
 Figure 7.4

Inside the scrubber simultaneously cooling, dedusting and pressure reduction takes place.

Wet gas treatment

The wet gas treatment is carried out in two stages, arranged in one vessel.
In the first stage (Pre-scrubber) the BF gas is quenched, precooled and prededusted by injecting water
into the gas via nine spray nozzles. The flow of upper five is 102 m 3/h and lower four is 127 m3/h (see
attached drawing A 061007SA0001).

The spray nozzles are arranged in a line and are centrally located inside the Prescrubber vessel.
Depending on the location the nozzles are spraying the water co-and counter-current to the gas flow
direction or in both directions.
After passing the Pre-scrubber the water is collected in the conical sump and discharged to the lounder
via the level control equipment.

In the second stage of Annular Gap scrubber the final cooling and de-dusting takes place. Key parts of
this stage are three AG-elements flanged to the gas pipes connecting the Pre-scrubber-stage and the AG-
scrubber-stage.

79
Water-injected by a spray nozzle (flow rate 170 m 3/h) located in the connecting pipe upstream the AG-
element and the pre-treated gas from the Pre-scrubber have to pass the annular gap. The injected water is
collected in the conical sump of the AG-scrubber and recirculated back to the five upper nozzles of the
Pre-scrubber via the recirculation pumps.

Fluctuations in BF top pressure are controlled by moving the inner cone up or down hydraulically. The
hydraulic cylinders are located in the bottom enclosure of the scrubber shell underneath the AG-scrubber
conical sump. The hydraulic cylinders and the AG-elements are connected by a rod.
The lead-in of the rod through the conical AG-scrubber bottom is gas tight scaled by an adjustable
stuffing box. To prevent the AG-elements to be closed completely a hydraulic stop is limiting the gap
width to 10 mm.At normal operation conditions all three AG-elements will be moved in parallel. In case
of a failure of one AG-element this AG-element will be blocked in its momentary position and the
remaining two AG-elements will control the top pressure. In case of a breakdown of the two hydraulic
pumps, accumulators are foreseen that will allow for one stroke for each element.

Advantages of AGS
oHigh dust particle separation efficiency with minimum gas pressure loss
oHigh efficiency cooling of the gas
oDesigned for long operational life and ease of maintenance
oProvided with shell protection to suit the expected plant operations and gas properties
oEfficient furnace top pressure control

A G Element –Technical data

Number of annular gap elements 3 pieces
Largest diameter, bell Ø1000 mm
Largest diameter, Venturi housing Ø1400 mm
Maximum stroke of the annular gap elements 500 mm
Lifting cylinders 160/110 x 500
Smallest annular gap 10 mm
Each AG-element (Figure 5) consists of an outer conical casing and an inner cone forming an annular
gap. By longitudinal movement of the inner cone inside the fixed conical casing the gap width can be
changed.

Figure 7.5: AG element

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The conical element, which is axially adjustable and which forms an annular gap together with its
conical shell. Only one spray nozzle, arranged centrally and spraying unilaterally, is installed upstream
of each element. It is the same type of nozzle with interchangeable nozzle insert which is also used in
pre-scrubber. The adjustment of the conical body makes it possible to alter the annular gap cross-section
and optimally match the removal of dust and the required reduction of pressure to the operating
conditions at the time. Fluctuations in BF top pressure are controlled by moving the inner cone up or
down hydraulically. The hydraulic cylinders and the AG-elements are connected by a rod.

The adjustment of the AG elements takes place with the aid of hydraulic actuators and an accompanying
hydraulic station. The cylinder retracts to open the AG elements and extends to close them

To prevent the AG-elements to be closed completely a hydraulic stop is limiting the gap width to 10 mm.
At normal operation conditions all three AG-elements will be moved in parallel.In case of a failure of
one AG-element this AG-element will be blocked in its momentary position and the remaining two AG-
elements will control the top pressure.In case of a breakdown of the two hydraulic pumps, accumulators
are foreseen that will allow for one stroke for each element

7.4 Demister
A certain amount of water droplets - formed in the AG-scrubber - will separate out in the AG-scrubber
sump by gravity.
The remaining water droplets (over 50 %) carried over are removed by the vertical demister by
centrifugal forces. The water will be collected in the conical sump of the demister and is recirculated
back to the five upper nozzles of the Pre-scrubber via the recirculation pumps.
This device reaches drop content in outlet gas less than 5 g/Nm 3; this value is low enough for
downstream equipment.

Demister – Material details

Demister shell P 265 GH or SA 516 Gr 60 / 70
Demister vanes Stainless steel
Foundation Anchor bolts 8.8
Flanges SA 105 / SA 516 Gr 60/70

7.5 Water system of GCP

Water System-Technical data

Scrubbing water total from water treatment 1018 m3/h
plant
Recirculated from sec. stage to quencher 510 m3/h
Recirculation pumps to quencher 1 + 1 stand-by
Flow rate of each pump 550 m3/h each
Total head 7 bar
Speed 1,480 rpm
Motor power 132 kW

81
 Water quality from water treatment plant
Temperature 35 °C
Pressure at ground level 7.0 bar g
PH 7 - 8.5
Suspended solids 50 ppm
Hardness 150 ppm (as CaCO3)

The water is injected by spray nozzles into the scrubber. There are two water loops.

Clarified water loop

The clarified and cooled scrubbing water is supplied by the cold water pumps to nozzles 6 to 9 in the PZ
scrubber and to the 3 nozzles (10-12) of the AG scrubber. The waste water is recirculated via the conical
sump of the Pre-scrubber and discharged via a launder to the waste water treatment system (pumps, etc.),
thickeners, hot water tank, hot water pump and cooling towers.

Recirculating water loop

The recirculation water is discharged from the AG-scrubber and demister sump and is supplied to the
nozzles 1-5 by the recirculation water pumps. The level control system in the level control tank balances
the recirculation loop.Two pumps, one in operation one stand-by, are available for the recirculation water
loop.The control butterfly valve (LCV 8010) in the recirculation water loop is controlling the water level
of the AG scrubber.

Water Treatment plant

The Water Treatment Plant is designed to treat the slurry water coming from the scrubber. The slurry water
is by gravity discharged to the two thickeners; each thickener is able to treat the 100% of the incoming
water flow rate. The water enters with about 3500 ppm of suspended solids and leaves the thickener with
less than 50 ppm.The treatment process is improved by correcting with caustic soda the water pH and by
adding polyeletrolyte.The thickeners are single arm type with peripheral drive bogie and central bearing,
reinforced concrete basin, with flocculation zone surrounded by a concentric outer clarification zone. The
clean water, together with the blow-down water coming from the B.F. cooling system is discharged by
gravity to the cooling tower.

7.6 Hydraulic system

The hydraulic units for the water butterfly valves and AG elements are fed from the central hydraulics
room, which is located in the bottom part of the scrubber.

Pressure generating station

The hydraulic station comprises 2 pressure pumps, an oil tank including filter, heating and cooling unit
and circulating pump, accumulator station, and diverse filters. All hydraulic equipment is located in the
bottom part of the scrubber.

Oil tank with recirculation system

The oil tank has a volume of 1500 l and is equipped with three contacts for oil level Control. The internal
circulation circuit comprises a pump, filter, cooler and heating System.
I.) Circulating pump to treat the returning oil
II.) Filter
Filter size: 5 μm

82
 The readiness for operation of this filter is monitored by differential pressure switches. If clogging
occurs, the message ”Filter clogged” is displayed in the central control room.
III.) Cooler to keep the oil temperature below app. 50 °C
IV.) Heating to keep the oil temperature above app. 20 °C

Circulation pump-details
Rating 2.2 kW
Pressure 10 bar
Speed 1450 r/min
Volumetric flow rate 90 l/min

High pressure pumps

Two hydraulic pumps, each with a rating of 55 kW, are available to generate a hydraulic pressure of 190
bars .The second pump is engaged only for about 2 min if the pressure drops below 185 bars. If the
pressure drops below 175 bar for a pre-set time (about 10 sec.), the system is automatically shut down,
the message”System blockage” will be monitored.

High pressure pump-details

Rating 45 kW
Volumetric flow rate 140 l/min
Speed 1475 r/min
Pressure 190 bar

In the main oil loop additional 5 μm and 10 μm filter unit will be installed. The readiness for operational
of this filter is monitored by differential pressure switches. If clogging occurs, the message”Filter
clogged” is displayed in the control room.

Accumulator station
Four accumulators, each with a nominal capacity of 50 l, are installed supplying sufficient pressure to
move the butterfly valves and AG elements to the safe position in case of pumps fail.

7.7 Gas Network

The clean gas network is shown in gas flow diagram (Refer figure1).

The clean gas of volume 550000 Nm3/h at pressure 2.5 bar from demister goes to TRT.After TRT due to
expansion and temperature reduction the volume of gas becomes 575000 Nm 3/h.The pressure after TRT
reduced to 0.1 bar.In case TRT is not functioning then AG element control the pressure.

After TRT there are two pipe lines one for stove (volume: 179000Nm3/h to 206000nm3/h, P: 0.1bar) and
other for PCI (Volume 9200Nm3/h to 10000Nm3/h, P: 0.1 bar).

There are other three pipe lines one for power station (volume 353000 Nm 3/h to 386000 Nm3/h, P: 0.1
bar), second one for Flare stack (designed for Volume 575000 Nm 3/h, P: 0.06 bar) and third one goes to
low pressure BF gas network (volume 353000 Nm3/h to 386000 Nm3/h, P: 0.06 bar)
There is pressure regulating valve in flare stack and BF gas network line. The gas will go to flare stack
only if there are excess gas produced or some of the system will down.

83
 9 Stoves
9.1 Introduction
Hot blast stove is used for converting cold blast at 150-200 0C from blower to hot blast between 900 0C to
1300 0C.

To ensure efficient furnace operation, the required flow-rate and temperature of the blast air must be
maintained. Typical industrial flows are 3000-10000 Nm3 per minute at temperatures of 1000-13000C,
depending on the size and type of furnace. This hot air provides up to 40% of the blast furnace sensible
heat requirement. The hot blast is supplied by regenerative heat exchangers, the hot blast stoves (Figure1)

Figure 9.1: General arrangement of stoves in blast furnace

Types of Hot Blast stove

 Internal Combustion Chamber
 External Combustion Chamber
 Kalugin Stove

A stove undergoes through three cycles to provide hot air (Figure 2).

1. Heating: during this phase air from combustion air fan and gases from blast furnace, LD and coke plant
are burnt in combustion chamber for heating of stoves.

2. Isolation: Stove is taken from combustion to blast stage via Isolation or vice-versa. During this stage
stove is completely isolated with all valves closed.

3. Blast: In this phase cold blast enters through the cold blast valve & gains heat from checker bricks and
enter the furnace through hot blast main.

84
 Fig 9.2 : Stoves cycles

Checker bricks
Combustion chamber

Figure 9.3 : Horizontal cross section of stove

85
Status of Stove valves during operation
STATUS
Valves
Combustion Isolation Blast
Hot Blast Valves Close Close Open
Cold Blast Valves Close Close Open
Combustion Air Valves Open Close Close
Chimney/waste gas valves Open Close Close
L.D.Gas Line Valves. Open Close Close
Open Initially for
Pressurizing Valves. Close Close
opening Main Valve
Open Initially for
De Pressurizing Valves Close Close
opening Main Valve
B.F.Gas Line valves. Open Close Close

Stove Sequence for 3 Stove Operation

Stove - 1 Stove - 2 Stove - 3

On Blast On Gas On Gas
On Blast Isolate from Gas On Gas
On Blast Compression On Gas
On Blast On Blast On gas
Isolate from Blast On Blast On Gas
De-compression On Blast On Gas
On Gas On Blast On Gas
On Gas On Blast Isolate from Gas

A stove is in one of three states at any given time: either on-gas, on-blast, or bottled up (ready and waiting
to be put on-blast).

H BF Stoves

Stove Dimensions
Cylindrical shell internal diameter 10.7 m
Dome shell internal radius 6.0 m
Dome refractory internal radius 5.3 m
Checker chamber cross section area 50 m3
Combustion chamber area 163 m3

86
 Stove Parameters
No of stoves 3
Type of stove Internal combustion chamber
Dome type Mushroom dome
Heat exchange surface area 72868 m2
Heat Recovery System Heat pipes (Direct)
Blast Volume 360,000 Nm3 / Hr at 1250 0C
Standard operation 1 on Blast, 2 on Heat
Blast time 30 mins
Gas time 52 mins
Changeover time 8 mins
Maximum dome temp 1400 0C
Burner type Ceramic
Mixing chamber for each hot stoves Single
Pilot burner Automatic
Combustion air fans 3 (2 W + 1 S)
Cooling for hot blast and back draft valves Water cooled

Stove shell details Stove Cylindrical Portion

(16 Rings)

Fig 9.4 : Stove shell details

Stove Dome Portion

87
88
Stove Refractory

Fig 9.5 : Refractory in Hot Blast stoves

89
90
Energy Recovery Systems
Purpose
 Heat BF Gas and/or Air with heat from Waste Gas
Benefits
 Reduce Waste Gas Temperature from 350°C to 125 - 150°C (avoid water
condensation – higher than dew point)
 Reduces Amount of Enriching Gas

Fig 9.6 :Waste Heat Recovery System Diagram

The process flow diagram is shown in the attached drg no. 061003G02003_A

91
Combustion air fan
Stove Parameters
Functional characteristics
ambient air, directly sucked from the
Type of fluid
environment
Thermohygrometric conditions - Summer season
Maximum Temperature 47.7°C at RH 40–100%
Normal Temperature 43°C at RH 7075%
Thermohygrometric conditions - Winter season
Minimum Temperature 4°C
Normal Temperature 18°C at RH 5560%
Barometric pressure 98.92 – 100.66 kPa
Dust suspension (ferrous, carbon) 10 mg/Nm³
Design operating condition
Rotating speed min. 950 rpm, max. 1000 rpm
Flow rate (wet) 100 kNm³/h (32.6 m³/s max. at 47.7°C)
Relative static pressure at delivery section 1200 mm H20
Expected life 100000 h

Ceramic burner
The ceramic burners are installed inside the
combustion chamber allowing vertical and
horizontal expansion independently from
the surrounding ring walls. The burner will
be capable of completely burning the air
and B.F. gas mixture, within the
combustion chamber, with firing rates
ranging from 20 to 100% of the burner
capacity. Due to their design, the ceramic
burners have an excellent acoustic damping
characteristic and cannot be considered as a
source of pulsation. The refractory grades
for the ceramic burners are especially
developed for high temperature
fluctuations. The ceramic burner are shown
in Figure 7. Burner must have Pilot Burner
and Operate Over a Wide Range of
Calorific Values.
Fig 9.7 : Ceramic burner

It must Prevent Pulsations Due to Incomplete Combustion

 Pulsations Caused by Harmonics with Either the Gas or Air Supply
 Prevented by putting pulsation dampers

92
Cooling for Stove Valves
Water cooling arrangement is provided in the following valves
o 3 nos. hot blast valves (Body & disc cooling)
o 1 no. back draft valve (Body & disc cooling).

Figure 9.8: cooling circuit for hot stove valves & back draft valve

93
 10 Coal Injection
Advantages of Coal injection
o Increase in productivity
o Higher O2 enrichment leading to lower blast requirement
o lower specific gas consumption
o Hot metal quality – Better Si % and Hot metal temperature
o Heat load and gas distribution – Shifting of temperature
o zone & decrease of gas flow to wall results in lower cooling losses
o Coke replacement

What is desired for coal injection in a Blast Furnace

Pulverized coal of
o Grain Size: 80% below 90 µm
o 100% below 500 µm
o Final surface moisture < 1%
o Mill Capacity – 60 t/h
o Injection rate -160 kg/thm (avg)
o 200 kg/thm (peak)

What is available with us:

Coal Properties Imported type coal Own coal (West Bokaro)

VM % 15-17 27

Moisture % 15 15

Ash % 10 16

HGI 50-55 50-55

Tentative grain size distribution (typical)

Maximum size, mm 50
Minus 30 mm 95%
Minus 6 mm 65%
Minus 3 mm 45%
Minus 1 mm 35%
Minus 100 mesh 5%

94
 Pulverized Coal Injection Plant

Raw Material Pulverized coal Pulverize Coal

Handling preparation Injection

Drying gas Pulverize coal

Ground hopper production screening

Coal grinding and Pulverize coal

Coal Conveying drying storage

Raw coal storage Coal and gas Pulverize coal

and feeding separation transfer

Raw coal handling section

The coal handling plant consists of a coal ground hopper and a belt conveyor for the handling of coal from
the ground hopper to the raw coal silo.

The ground hopper has been suitably located in the general layout considering ground elevation. The
hopper, concrete made, has a capacity of about 40 m³ .

One metal detector and one magnetic separator is arranged on the main raw coal belt conveyor. A sensor is
installed at about 3m from coal feeding to detect the presence of ferrous particle along with the raw coal.
The sensor signal will energise the magnetic separator, installed at a location upstream the sensor, and
pick up the ferrous particles which will be removed by a cross belt conveyor and discharged to a bin
located at ground level through a chute.
The conveyor idlers below the magnetic separator are of non-magnetic stainless steel for smooth operation
of the system.

The coal preparation plant consists of one raw coal silo, 600 m3 capacity, with rod gate at the bottom of
the silo and an expansion joint between the rod gate and a drag chain conveyor.

Raw coal grinding and drying section

The raw coal grinding and drying section consists of a coal vertical roller mill, fed by a drag chain
conveyor (normal capacity 72 tph with design capacity of 80 tph) through a chute. The raw coal silo will
have a rod gate at the discharge and the coal will be fed through the rod gate to the drag chain feeder.
Finally, the raw coal will be fed to the grinding mill by means of chutes suitably designed for this purpose.
The chain link will be of low alloy steel with hardness of 50-55 HRC.
The coal feed rate into the mill is controlled/metered through variable speed drive of drag chain conveyor.
The indication for the actual feed rate to the mill is obtained from the in weight of the pulverised coal silo.

95
The raw coal mill is located below the drag chain conveyor and is supposed to grind the coal from a
maximum size of 50 mm to the desired grain size.
Drying of coal is envisaged through a hot gas generator, which will heat up the circulating flue gas as per
process requirements. The pulverize coal leaves the mill from the center pipe with gas stream through
dynamic classifier where oversize material separates from the fines and further re-circulated for grinding.
H Blast Furnace coal mill is Pfeiffer make vertical roller mill “KMP380 S” with a capacity of 60 tph. It
has a drive of 730 kW which enables mill table to rotate with 19.1 rpm with the help of suitable gearbox.
This grinding mill has unique feature of hydraulically liftable rollers, hydraulic tensioning of rollers and
replacement of wear parts with lift and swing mechanism.

Fig 10.1: Typical vertical roller mill

B1.1.1 Radial fan shall be used for the seal air system of the rollers. Compensators and dust filters shall be
included in scope.
B1.1.2 The details of the fan are as under:

96
  Fluid: Ambient Air
 Seal Air Flow: bidder to indicate 1000 nm3/h
 Maximum speed: 3000 rpm
 Drive system; direct drive

A bag filter unit located on the top of the fine coal bin separates coal and flue gas. The gas is then, by
means of an ID fan installed downstream the bag filter, partly discharged to the chimney and partly re-
circulated to the inlet of the hot gas generator.

Fig 10.2 : Closed loop grinding and drying system

The hot gas generator consists of a refractory lined chamber equipped with a burner using blast furnace
gas as fuel and coke oven mixed gas as ignition gas. The HGG has turn down ration of 1:6 with BF gas
having min and max capacity 2.08 G Cal/hr and 12.5 G Cal /hr respectively and it has turn down of 1:3
with CO gas having min and max capacity 0.9 G cal/hr and 2.7 G Cal /hr respectively.

Technical data of HGG:

Total Heat 12.5 G Cal/hr

Turn down Capacity G Cal/hr
Min Max
CO Gas 1:3 0.9 2.7
BF Gas 1:6 2.08 12.5
BF Gas flow in Kg/hr
Min 22000
Max 3663
CO Gas flow in Kg/hr
Min 178
Max 178
Hot Gas outlet temperature 348 0 C

97
The heating gas enters the mill using control dampers; the complete system allows the right mixture of
intake air, from the combustion air fan, and blast furnace gas.
To ensure maximum efficiency in operation of hot gas generator, two parameters
are of great importance:
 The “Air to Fuel” ratio to be kept to minimum to ensure complete combustion in limited time.
 The target temperature to be controlled at the mill outlet to obtain desired result from the system,
by mixing right amount of fuel and air, irrespective of load change.

The temperature of the carrier gas at the inlet of bag filter should be in the range of 90 to 100 °C.

Drying of coal is envisaged through a hot gas generator, which will heat up the circulating flue gas as per
.
Gas analysers are provided to measure the level of oxygen and CO concentration after the fine coal filter.
A further oxygen analyser is provided after the hot gas generator. When the plant is not in operation a CO
sampling, alternated with the previous one, will be done after the mill.

Fig 10.3 : Hot Gas Generator

Hot Gas Generator

Burner

Pulverised coal storage section

The coal dust laden gas passes through the bag filter, at the end of the drying and conveying line, where
the coal dust will be separated in the bag filter hopper.
Through the rotary air lock valve, coal dust will be fed into a fine coal silo (capacity1000 m3/600 tons)
located under the bag filter through screw conveyors.

98
In case of failure of the preparation line, the quantity of coal stored in the silo will
guarantee a constant injection rate for about 10 hours with max injection rate of 60 tph, These 10 hours are
largely above the travelling time of descending burden materials into the blast furnace.

The storage silo is a welded construction with a cylindrical and a conical section and a flat roof. The cone
of the pulverised coal bin is fluidized via a fluidizing nozzles enabling easy discharge of coal into the feed
tanks.

Gas analysers (two for oxygen and one for CO) are provided to measure the level of oxygen and CO
concentration in the bin (the CO analyser is common to the one provided for the fine coal grinding plant).
In case the gas concentration is exceeded, then the nitrogen flow will be increased manually as long as the
limiting values go under the set value.Over pressure inside the silo generated by the de-pressurizing of the
injection vessels is released through the silo top filter.

Although the system is equipped with O2 and CO measurement devices, flame

front equipment downstream the mill and for bag filter is provided.

Fire prevention has been adequately taken care by the adoption of O2, CO
detectors and nitrogen flushing. Fire hydrant is provided around the PCI building.

Coal injection system

The injection system consists of the following equipment:

 Pulverised coal screening

 Injection vessels
 Pulverised coal transport line
 Distributor
 Pulverised coal injection lines
 Injection lances

Pulverised coal will be conveyed to B.F. at low speed. Non-wearing dense phase
pneumatic conveying, using (inert) nitrogen gas as conveying gas.

The conveying is done under dense phase conditions. At maximum injection

condition, the coal to gas ratio will be 40 – 45 Kg coal/N2 Kg about.

Pulverised coal screening

Between the pulverised coal silo and the bag filters, screening machines separate coarse particles, foreign
particles and agglomerates from the pulverised
coal which might block the coal flow in the injection lines. Rejected material is discharged via a chute into
a metallic box at the ground floor.

Injection vessels

Two injection vessels of approximately 35m3 capacity each will be used as feed tanks. During the
injection from the first pressurized vessel, the second has to be de-pressurised, filled, pressurised again
and has to hold before injecting again. This procedure will be repeated alternately.

99
The injection vessels is designed as cylindrical pressure vessels with conical bottoms and brackets for
vertical installation. They will be equipped with the necessary flange connections for valves and
transmitters and an inspection hole as well as a safety valve and fluidization devices in the lower cone
area.

Inlet and outlet valves are provided for opening of the vessel during refilling
and safe closing before pressuring starts.

The calculated sequence of a normal injection vessel cycle envisaged by one of the possible sub-supplier
includes:

- duration of 1 cycle 13.1 min

- coal filling 2.72 min
- pressurization 4.43 min
- depressurization 2.65 min
- Valve actuation time 3.3 mim
- Total time 13.1 min
When the injection period is completed, the vent valve opens and the vessel is depressurised into the top
of the fine coal silo. The vent flow rate is controlled ensuring that the speed is less than 20 m/s in order to
minimize wear inside the pipe.

Pulverised coal transport line

The pulverised coal transport system carries the pulverised coal from injection
vessels to furnace distributor. In this system, pulverised coal in the feed tank is forced into the coal
transport line by the nitrogen pressure in the feed tank. The global pulverised coal flow rate to be injected
into the blast furnace is controlled by a control valve (GrIztco valve) located downstream the injection
vessel.
Fig 10.4 : Typical methods of coal flow rate control

100
 Fig 10.5 : Coal injection through static distributor
The total flowrate is then distributed to the tuyeres by a static distributor without
individual coal flowrate control. At the distributor, the coal is evenly distributed to the injections lines
feeding the coal to the Blast Furnace tuyeres through length balance line.

Distributor
The pulverised coal is carried by conveying gas to the distributor that splits the conveyed mass in equal
streams to the injection lines. The distributor will be supplied with supports and studs for the
interconnecting piping. The distributor is located at a blast furnace tower platform at a buffer main level.

Fig 10.6 : A typical distributor

101
Injection lines to tuyeres
Coal injection may individually be shut-off in each single injection line. The relevant line is automatically
flushed and cooled with nitrogen, being the lance inserted in the tuyere stock. The unchanged global
injection flowrate is then equally re-distributed in the injection lines remaining in operation.

Fig 10.7 : A typical injection lance

Coal flow in the individual injection line is detected by a flow switch device. If no flow of coal is
detected, the relevant line is automatically shut-off, switched to cooling gas and purged in the portion
between the injection point of the cooling gas and the lance.

In case of a sudden blast reduction (pressure or flow rate) in B.F. operation below a set value, the coal
injection will be immediately stopped. All the shut-off valves located downstream the distributor will be
automatically closed and all the lines will be switched to nitrogen for cooling purposes. In case of blast
reduction for short time, the main line remains under pressure. If the blast reduction lasts longer, the main
line is to be purged backward.

The rate of coal injected to the Blast Furnace is detected and controlled by the change of weight of the
feed tank as coal discharges from the vessel. The PCI system is designed to inject the specified range of
the coal up to a desired
injection rate (60 t/h).

Each tuyere injection line is equipped with a positive isolation valve, located close to the bustle pipe, for
shutting down and isolating the system from the furnace. A check valve or manual shut-off valve is fitted
to each tuyere stock to enable the lance to be easily inserted and removed from the blowpipe. Flexible
hoses having sufficient length is connected to the lance from the fixed injection line piping.

Nitrogen consumption for PCI plant:

Nitrogen will be available at two pressures:

 High pressure, at 20÷42 bar g

 Low pressure at 4÷6 bar g.

Two buffer pressure vessels of 100 m3 each will be installed to meet the peak requirement of nitrogen for
emergency/flushing condition. One 90 m3 process pressure vessel will be installed near the injection plant
to cater regular requirement for injection purpose.
Total Nitrogen consumption for PCI plant is

102
HP consumption – 9,861 NM3/hr
LP consumption – 1,450 NM3/hr

Drawing for attachment

0610-60-G-02-002
0610-60-G-02-003
0610-60-G-02-004

103
10 SLAG GRANULATION PLANT

Introduction
The objective of the granulation plant is to convert liquid blast furnace slag into slag sand, a product
showing a considerable added value. The INBA assures the production as well as the dewatering of the
slag sand. The slag sand is used as raw material in the cement industry. The plant is designed to handle
slag, produced by the blast furnace, considering the variation in quantity of slag flow and sequence of
tapping. The process is based on “under pressure quenching” of the liquid slag withcold water.

The quality of the slag sand mainly depends on the initial temperature and on the chemical composition of
the liquid slag, on the slag mass flow, on the pressure and the temperature of the granulation water, as well
as on the geometric shape of the granulation blowing box.

Each cast house has an INBA slag granulation. One INBA system will be dedicated to the N & E tap holes
whilst the second will be common to the S & W tapholes.

Fig 11.1 : INBA Hot water granulation system

104
 H BF Granulation Technical Data
Hot metal production average 7150 t/day
Hot metal production peak 7850 t/day
Slag volume 310 kg/t-hot metal
Molten slag production max. 2,430 t/day
Number of taps/day for slag granulation 10 -12
Slag flow rate (max.) 8.0 t/min
Slag flow rate (peak) 10.0 t/min
Duration of slag flow 60 - 100 min/tap
Slag temperature 1500 ± 20°C
Granulation water pumps (per system) 2 x 1.000 m³/h
Specific gravity of granulated slag 0.9 – 1.3 t/m³
Average glass content of granulated slag ≥ 95 %
Size distribution of granulated slag more than 4.75 mm < 5%
Moisture in the granulated slag 10% after 3 hours in storage tank
Size: more than 95% of produced slag is between 0.2 – 0.3 mm

105
 Equipment Main Features
Blowing box o welded steel plate(material IS 2062 Gr A) construction with
flange for water pipe connection.
o perforated front plates with ceramic nozzles.
Granulation tank o welded steel plate construction (material IS 2062 Gr B).
o refractory concrete lining at the side walls, below blowing box,
on bottom of basin and in the area of the overflow.
o overflow with adjustable outlet.
Steam emission o welded steel plate construction Ø 6 / 3.5m (material IS 2002
stack Gr 2).
o Elevated emergency water tank of capacity 60m3.
Dewatering drum o Diameter: 5.0 m, length: 5.17 m.
o Deflectors inside dewatering drum.
o Filtering, supporting and bucket screens.
Lubrication devices o 2 oil pumps, fixed on pillow block for supporting wheels
o 2 oil reservoirs
o Drop distributor and tubes
Conveyor belt o Power: 45KW
inside drum (SCA1) o capacity : 500 t/h
o width : 1,000 mm
o speed : 1.7 m/s
o Slope: 170 max.
Conveyor belt o Power: 75 KW
(SCA2 o capacity : 500 t/h
o width : 1,000 mm
o speed : 1.7 m/s
Conveyor belt o Power: 15 KW
(SCA3 o capacity : 500 t/h
o width : 1,000 mm
o speed : 1.7 m/s
Storage bins (4 o Carbon steel construction equipped with slag discharge gates.
nos.) o Capacity 225 m3/each
10.1 Blow box Slag granulation
Liquid slag discharged from the blast furnace and separated from the pig iron flows through a slag runner
system towards the granulation tank(figure 1). At the blowing box, fitted below the end of the hot runner
spout inside the granulation tank, the molten slag is quickly cooled down by water jets.
Steam produced by the quenching process escapes through the stack. The slag water mixture flows to the
dewatering station by means of gravity. For safety reasons, an emergency water tank of 60 m 3 volume is
installed at the stack, providing granulation water with a flow rate of 600 m 3/h for 6 min. in case of an
emergency situation.

10.2 Dewatering Station

The dewatering station of the INBA granulation plant is installed immediately behind the granulation tank
nearby the cast house. The dewatering station consists of the distributor, the slow down boxes, the filtering
drum and the hot water tank below the drum. The distributor assures a regular repartition of the slag water
mixture on the entire length of the drum. The slow down boxes reduce the wear on the drum. A conveyor
belt inside the drum guarantees the continuous discharge of the dewatered slag sand. The drum itself is

106
composed of a cylindrical body in horizontal position. It is equipped with finely meshed filter screens;
these screens allow the water to leave the drum, but retain the slag sand efficiently.

Components of a Dewatering System

1 Dewatering drum
2 Distributor
3 Buckets
4 Conveyor belt
5 Purging water
6 Purging air
7 Supporting & Filtering
screens
8 Slag sand layer
9 Hot water tank

Fig 11.2 : Components of a Dewatering System

During the entire slag cast, a layer of slag sand builds up on the bottom of the drum; this layer acts as a
filtration medium and helps considerably to retain the biggest part of the small sand particles. As a result,
there is no slag wool and only a very poor amount of fine slag sand entering into the hot water tank. The
buckets fixed at the inside wall of the filtration drum pick up the slag sand; after a half revolution, the
sand drops on the conveyor belt, positioned on top of the distributor. The sand is distributed to four
storage bins by means of conveyor belts.

10.3 Water system

The water circuit of the granulation system is an entirely closed loop. Three granulation pumps deliver the
granulation water from the hot water tank below the drum to the blowing box. Depending on the slag flow
rate, one or two of the three-granulation pumps will be in operation. The third granulation pump is a
standby pump. The hot granulation water is recollected in the hot water tank, after having passed through
the filtration drum. The emergency water tank installed at the stack above the granulation tank provides
water for 6 min. in case of an electrical supply failure, a failure of the granulation pumps or an emergency
107
stop. Within these 6 min., the slag has to be diverted to the slag pit or the tap hole has to be closed. The
availableness of emergency water is guaranteed by a spring-loaded valve. Makeup water is required to
compensate water losses during the granulation and dewatering of the liquid slag. The makeup water is
fed from GCP WTP and if needed, from PIEZOMETRIC TOWER to the recovery tank. The demand for
makeup water is detected by the control of the water level inside the hot water tank and the recovery tank.
Beside the water losses, makeup water is also required for:

Gland water for process pumps

Drum cleaning
Storage bin cleaning
Filling of emergency water tank

Pump Details:
Pumps Type Q(m3/h) H (mWC) Power (KW)
Granulation pumps PGR 1 1000 29 132
PGR 2 1000 29 132
PGR 3(stand-by) 1000 29 132
Drain pumps PDR 1 50 7.4 2.6
PDR 2 (stand-by) 50 7.4 2.6
PDR 3 100 23 23
PDR 4 ((stand-by) 100 23 23
Recovery pumps PRY 1 200 7.7 6.5
PRY 2 (stand-by) 200 7.7 6.5
Booster pumps PB 01 40-50 60-58 18.5
PB02 (stand-by) 40-50 60-58 18.5
Centrifugal pumps CP 41 A 300 30 37
CP 41B (stand-by) 300 30 37

Two booster pumps are installed to provide the required pressure for gland water as well as for the drum
and storage bin cleaning. One of the pumps is used as standby. The selection of the standby pump will be
changed regularly.

A recovery tank of 420 m3 volume is installed behind the dewatering station. The overflows of the
granulation tank, the drum and the hot water tank are connected to this tank. In case of a failure, the
overflowing process water as well as the emergency water will be collected here. Further, all drain pumps
of the installation are connected to the collecting tank. Drain pumps are installed in the cellar below the
drum and in the storage bin area. The collected water will be used as makeup water and is pumped to the
hot water tank when makeup water is required.

10.4 Slag sand conveying and storage

The slag sand drops from the filtration drum buckets onto the conveyor belt installed inside the drum. This
belt discharges the slag sand to a second conveyor belt leading to the top of the storage bins. The selection
of the four storage bins is done by means of a movable and reversible conveyor belt installed on top of the
storage bins. Each bin has a capacity of 250 m3.

In addition to the storage bins, there is a stock pile, which can be used in case no storage bin is available.
In case of a failure on the storage bin conveyor belt, the slag sand can be discharged directly to one
specific storage bin, bypassing the storage bin conveyor belt by means of a diverting gate through a

108
distribution chute. The storage bins are also used for a secondary dewatering, in order to reduce the
residual moisture of the slag sand. After a delay of 2 hours the slag sand is dry enough to be discharged.

Attached Drg No.061006G02001

109
12 Utilities
Purpose of cooling
Blast Furnace cooling system has objective of protecting the furnace shell and increasing the campaign
life.
Over the years number of cooling methods has been adopted to cool the furnace shell. The earliest
methods, shower cooling and jacket cooling relied on extracting heat through shell to the cooling medium.
However, in extracting heat through the shell , high thermal stress can be developed. For this reason these
methods are used in areas of low heat flux, such as the furnace hearth.
The most important development in furnace cooling methods came with the use of intensive inserted plate
cooling and staves designs. Both these system extract heat from furnace before it reaches on the shell and
therefore, the thermal stresses on the shell are reduced.
H Blast Furnace is designed for stave closed loop cooling to get better campaign life.

12.1 BF Water Cooling System

Description
The primary BF cooling is with demineralised water closed loop system. There are four circuits for
satisfactory cooling of the Blast Furnace. Secondary, tuyere emergency and leakage compensation system
for any cooling member will be with industrial water.
The hearth will be stave cooled and the hearth bottom cooling will be with one layer of water pipes
located under the bottom plates.The tuyere breast will be cooled with cast iron staves. In order to obtain a
very good heat transfer and to insure a safe operation of the blast furnace throughout all the campaign, the
shell of the bosh, belly and up to lower shaft will be cooled with copper staves. The BF walls, from
middle shaft to R3 staves, will be cooled with 6 rows of cast iron staves.
The drawing N° WS1 shows the philosophy of demi-water distribution among the various cooling
elements, with the design figures for flow rates of the water cooling the different BF sectors and the
maximum temperature increases on each circuit considered for the sizing of the heat exchangers.

Description of all circuits are shown below:

Circuit Area Cooled Flow

Circuit #1 For hearth cooling, underhearth and tap hole. 1145 m3/h.
Circuit #2 For the tuyere bodies, tuyere coolers, tuyere nose, HBV 3094 m3/h.
and probes.
Circuit #3 For eight rows consisting of four rows of cast iron staves, 2500 m3/h.
tuyere (T) staves, upper shell (S3÷S5) staves and four
rows (B1-B2, S1÷S2) of copper staves from bosh up to
mid-stack.
Circuit #4 For three rows of cast iron staves (R1÷R3). 320 m3/h.

The total amount of demineralised water circulating around BF proper will be 6739 m3/h.

Primary circuits

110
Circuit #1 (Low Pressure Circuit)
The DM water coming from the operating circulation pump (1,145 m3/h) will be split in
three streams.
The first one (657 m3/h) will cool the four rows of hearth staves in cascade.
The second one (408 m3/h) will cool the under hearth cooling system in 14 headers of four passages
arrangement.
The third one (80 m3/h) will cool all four tap hole staves.
The total discharged cooling water will be sent through the main pipe to the expansion
tank and from this to the heat exchangers and to the suction of pumps.
The expected ∆ T for this circuit is 6 deg. and expected heat load is 6827.8 M Cal/hr
Circuit #2 (High Pressure)
The DM water coming from the operating circulation pump (2,968 m3/h) will be split in two streams.
• Low pressure (8 bar and 2030 m3/h) to tuyere body, tuyere coolers, hot blast valves, back draft valve.
• High pressure (11.5 bar and 1,065 m3/h) to tuyere nose, furnace probes.
The total discharged cooling water will be sent through main pipe to the expansion tank and from this to
the heat exchangers and to the suction of pumps.
Total expected ∆ T for this circuit is 5.7 deg and expected heat load is 14080.8 M cal/hr
Circuit #3 (High Pressure)
The DM water coming from the operating circulation pumps (2500 m 3/h) will be sent to the cast iron
staves / cooper staves feeding headers. The circuit is divided into four sectors.
From this ring the water enters from T stave and cascaded to the corresponding vertical pipes of staves
upto S5 row staves.
The discharge cooling water is collected to the expansion tank and from this to the heat
exchanger and to the suction of pumps.
Total expected ∆ T for this circuit is 13.2 deg and expected heat load is 33000Mcal/hr
Circuit #4 (High Pressure)
This circuit is designed for hot water cooling of R1-R3 staves.
The DM water ( 70-80 deg) coming from the circulation pumps (320 m 3/h) is divided into four sectors.
The pressurized water in each sector flows through the feeders of cast iron staves (R1÷R3). The out let
temperature of water is about 90 deg. This water gets recirculated after passing through the expansion tank
with out heat exchanger. Cold water at 45 deg from circuit#3 is poured into circuit # 4 expansion tank for
the purpose of make-up and temperature compensation. Same amount of additional hot water at 90 deg is
sent back to circuit#3 expansion tank.
Total expected ∆ T for this circuit is 11.3 deg and expected heat load is 3616 Mcal/hr

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Leakage compensation circuit:
There is provision of industrial water header for tuyeres and staves. This water will be used for cooling of
damaged / leaky members. Specific leaky member will be disconnected from the closed loop and will get
industrial water. The discharge of this water will be connected to the open trough and will be fed to
GCP/slag granulation plant.

Demineralised water make-up

De-mineralized water stored in a storage tank (100 m3, 2 numbers) will be fed to different circuits , as per
requirement, with the help of 4 slow filling pump of 15 m3 and 2 fast filling pump of 50 m3 each. These
pumps will get started after getting feedback from the expansion tank water level.

Emergency cooling during power failure

During power failure, the required amount of water will be supplied by diesel pumps; the water flow-rate
supplied by the diesel pumps is specified here below:
Circuit #1 - 580 m3/h as demineralised water
Circuit #2 - 1532 m3/h as demineralised water
Circuit #3 - 1250 m3/h as demineralised water
Every circuit diesel pump is designed for 50% of the total flow requirement of that circuit.
In case the diesel pumps fail to start, a back-up emergency system will supply water. An overhead tank
(900 m3) will provide water at reduced flow rate for 20 minutes.

Emergency top spray cooling system

Consisting of no. 2 pumps (1 working + 1 in stand-by), flow rate = 120 m3/h, head = 100
mWC, is there in order to cool, with industrial water, the top part of the blast furnace in case of
emergency.

Pumping station
The new pumping station will be equipped as follows:
 Circulating pumps
The main circulating pumps serve for keeping the circulation of cooling water through the
cooling elements and the re-cooling system in the cooling circuit.
The following table resumes the characteristics of the main pumps that will be installed in
the new pump house.

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113
The heat exchangers will have the following features:
• SS316 plates (minimum0,5 mm thick)
• 10 % extra plate for failing

Cooling towers
The secondary hot water from the heat exchangers is equally distributed into the 5 cells (4working +1
stand by) of cooling tower. This water is again re circulated with the help of pumps to cool DM water of
primary circuit.
Design basic data for cooling towers:
No. of towers 1
No. of cells for each tower 5 (4 working + 1 stand-by)
Amount of cooling water 6,454 m3/h
Inlet T (°C) 44
Outlet T (°C) 34
Wet bulb temperature(°C) 28.5

The tower structure will be made of concrete. A chemical dosing plant will feed the chemical components
into the cold well in order to neutralized water.
Accessories
No. 5 (4 w + 1 S) auto back wash strainers Q = 1653 m3/h each
No. 2 sand pressure filters, material carbon steel
Flow rate 300 m3/h each
Equipped with
• Feeding pump Q = 600 m3/h .H = 20 m WC
• Backwashing pump Q = 390 m3/h .H = 20 m WC
• Backwashing air blowers (2+1) Q = 960 Nm3/h .H = 600 mm WC
Demineralization plant
The plant will be made by two lines (1 working + 1 stand by) of capacity 10m 3/h each (final conductivity
5 µs/cm) and is composed of
 1 cationic exchanger, carbon steel made and PVC internal lined
 1 anionic exchanger, carbon steel made and PVC internal lined
The plant will be controlled by:
 1 centralized control board
 1 conductivity meter
 1 pH meter
Regeneration and neutralization system (common to both lines) is composed of :

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  2 chemical dosing units complete of storage tank and injection equipment
 1 control board
Neutralized water will be released, by gravity, and will be discharged to SGP.
Demineralized water storage tank and pumping station Includes:
 2 demineralized water tank, volume 100m3 each, carbon steel made and internally rubber lined.
 6 electrical motor driven pumps, 3 of 15 m 3 and 3 of 50m3 for the make up service to the
expansion tanks as and when required
 1 electrical motor driven pumps for overhead tank (900 m3) quick filling Q= 100
m3/hr .H = 70 M W.C which will be used for emergency purpose.
 1 electrical motor driven pumps for re-circulation in EOHT (capacity 10m3/h)

12.2 Other Utilities

In addition to the Primary (Dematerialized) and secondary (Industrial ) water for H BF, the following
utilities are required
 Oxygen
 LP Steam
 Mixed CO gas
 LD gas
 Compressed air
 Instrument air
 LP Nitrogen
 HP Nitrogen
 Water Type Fire Extinguisher
 Portable Water

All the utilities will be provided to H Blast Furnace as per the following table:

Pressu Flow
Temp. TOP
# Service re Unit
(ºC) proposed Peak
bar(g) Avg
S 486.210 Nm3/hr 575
Low Pr. Network 0.06 50 max. 390
E 1733.25 *1000
BF Gas (BFG)
575
1
S +484.40 Nm3/hr
0.1 50 max. 390
High Pr. Network E +1647.00 *1000
BF Gas (BFG)
298 at 380
S 482.810 Nm3/hr
5 Blower 290
E 1760.231 *1000
2 Cold Blast (CB) end
Coke Oven Gas 0.05 - S+483.50 1700
3 Nm3/hr
(COG) 0.105 - E+1757.495 600

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 0.12 - S+484.810 12000
Nm3/hr
4 LD Gas (LDG) 0.15 - E+1645.50 7,000
Oxygen, HP 25000
S+481.10
5 (For emergency 20 - 32 - Nm3/hr 15000
E+1756.746
operation only)
Oxygen, LP 25000
S+482.05
(For normal 6.5 - 8 - Nm3/hr 15000
E+1757.246
6 operation)
S+482.80 11000
7 Nitrogen, HP 20 - 42 - Nm3/hr 7000
E+1756.746
S+481.70 5400
Nm3/hr
8 Nitrogen, LP 4-6 - E+1757.246 1100
S+481.035 60
9
L.P. Steam 10 - 15 290 - 315 E+1756.745 t/hr 18
Clarified water for 400
10 1 Ambient S684 E 1710 m3/hr
Make up, (CW)
11 Drinking Water 1 Ambient S 585 E 1595 m3/hr 5

Industrial water (Clarified Water)

Industrial water from the main network will be collected in make-up water tank from where it will be
distributed to

1. Pumped to an elevated tank (+ 40 m), of 500m3 capacity with the help of two number horizontal
centrifugal pumps (Operation 1, Stand-by 1) with flow rate 400 m3/h each. From here water will be
mainly used for make up water for BF secondary cooling, DM water production, slag granulation make
up water and for other services like toilets, HVAC, and cleaning purposes in other area of blast furnace.
The return water will be re-circulated through cooling tower.

Reference drawings: 0610-45-U-01-001, 0610-80-U-01-001

2. To Spray Injection with the help of two pumps (one working one stand by) of 120 m3/hr which will be
in emergency when top gas pressure will increase from the desired value.

3. Backup Circuit for Leakage Compensation with the help of two pumps of 150 m3/hr. This will be used
in any cooling member when it is damaged / leaky.

Oxygen

The oxygen is distributed at Low pressure of 6.5 -8 brag for following uses.

 Cold Blast injection 15000 m3/hr to 24000 m3/hr.

 Other plant services max 1000 m3/hr

Reference drawings :0610-80-U-01-004, 0610-80-U-01-011

LP Steam

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 LP will be used for cold blast injection, purging the gas mains and blast furnace , heating of some
valves and for other services. In order to reduce the steam pressure for distribution system one steam
pressure reducing station will be provided.

 Capacity (normal) 15 t/h

 Capacity (peak) 44 t/h
 Inlet pressure 12 ÷ 15 bar
 Max temperature 290 ÷ 315 °C

Reference drawing: 0610-80-U-01-005

Mixed Coke Oven Gas

The supply quantity of CO gas is fixed to 1700 m3/hr considering the global gas balance of the plant. It
will be used for pilot burners and heating of troughs. Pilot burners will consume CO gas all the time
while others will be used intermittently. The main consumer points are:

 Stoves Pilot Burner 60.0m3/hr

 Flare Stack Pilot Burner 60.0m3/hr
 BF top ignition 50.0m3/hr
 Cast House Iron Runner Heating 1500.0m3/hr
 P.C.I. 1020.0m3/hr

Reference drawing: 0610-80-U-01-006

LD Gas
Reference drawing 0610-80-U-01-010
It will be used for enrichment of BF gas for firing in the stoves.

Compressed Air

Two air compressors (1 working +1 stand by), with flow rate Q = 5000 Nm 3 /hr will be installed to meet th
compressed air requirement of Blast Furnace. The compressed air will be delivered at 6 bars. As the compresse
air is wet, air dryer of approximately Q = 3500 Nm3/h will be provided to meet the requirement of instrument ai
Rest compressed air will be utilized for other services of blast furnace.

Reference drawings: 0610-80-U-01-008 , 0610-80-U-01-007

Nitrogen

Nitrogen is mainly used for gas line purging during emergency or maintenance, carrier gas for
pulverize coal injection, purging of PCI plant, pressurization / blanketing of cooling water expansion
tank, BLT gear box secondary cooling, back up for instrument air and for instrument/camera cooling.

Three dedicated pressure vessels of Nitrogen (two of 100 m3 and one of 90 m3) are provided to meet
the peak requirement of PCI plant during emergency / flushing.

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 Nitrogen will be available at two pressures:

 High pressure, at 20÷42 bar g

 Low pressure at 4÷6 bar g.

Reference drawings: 0610-80-U-01-002, 0610-80-U-01-003

Water Fire Extinguishing System

The fire fighting distribution network, coming from the T.O.P. of clarified water that feeds a reservoir.
A pumping station, from the tank feeds the various areas to be protected. The network is always kept
under pressure by means a pressurized tank, equipped with jockey pump and air compressor, to
compensate water leaks or small consumption. In case of fire the main pumps will start automatically.
Three categories of fire hazard zones shall be there in the blast furnace area

 High hazard category,

 Medium hazard category,
 Low hazard category.

Fire water pumps

 No. 2 (two) horizontal centrifugal pumps, (Operation 1 + 1 Stand By)

 No. 1 (one) horizontal centrifugal pump, equipped with Diesel motor.
 Compressors ( 1 Working + 1 Stand By)

Classification

a) High hazard category

 BF proper: One point each at every platform and four point at each corner of tuyere platform.
 Stock house: One point at each of the four platforms of Stock House.
 Nut coke recirculation building: one point each at two nos. platform.
 Cast house floor: Four point at each corner of cast house floor.
 Stove: Three points.
 Gas cleaning plant: one point at dust catcher, two points at scrubber one point in TRT building.
 Pulverized coal injection plant: One point at each of 10 floors.

b) Medium hazard category

 Stock house MCC room: One point each at four stair case landing.
 Main electrical room: One point each at five stair case landing.
 Cast house dedusting & slag granulation electrical building: One point at stair case landing.
 Water treatment MCC room: One point at stair case landing.
 PCI MCC room: One point each at two stair case landing.
 Main Receiving Station: One point each at two stair case landing.
 Hot blast stove heat recovery building: One point.
 Hot blast stove hydraulic, lubrication & instrumentation building One point.
 Gas Cleaning Plant hydraulic & instrumentation building: One point.
 DG room: One point.

c) Low Hazard category

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 Water treatment pump house: one point
 Fines silo - one point to be provided.

Portable Water

The cold drinking water will be delivered to the users, by the use of no. 2 chillers
(1 working + 1 stand by) and no. 2 centrifugal pumps (no. 1 working + no.1 stand-by).

Distribution of chilled water to various location is given below

 General Office
 Canteen
 Main Electrical & Control Room
 B.F. Office
 Main Receiving Station
 Water Treatment Plant Electrical Building
 Cast House
 PCI
 Spare Parts Building
 Laboratories
 Stock house

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12 Electrics, Instrumentation & Automation
12.1 Electrics
ELECTRICAL
Electric power supplied at 33 KV, 50 Hz is fed from the 33 kV switchboards of MPDS # 4 to main 6.6 kV
switchboards at LBSS which is the main receiving station for H Blast furnace. The electrical distribution
of H furnace is shown in Annexure-E1. The system is constituted of 6.6 kV HV-MCC’s, 415 V PCC’s and
415 V MCC’s located at main electrical buildings viz. Blast Furnace Load Center (BFLC), Water
Treatment Electrical Building, Stock House Electrical Building, PCI electrical Building. 415 V PCC are
fed from HVMCC, via 6.6/0.433 kV distribution transformers installed in the electrical rooms

8 nos. of outgoing feeders of LBSS 6.6kV Bus supplies the 3 nos. HT MCC’s and 2nos. WT transformers.
The HT MCC’s are namely,
1. BF- HV MCC#1
2. BF-HV MCC#2
3. SH-HV MCC

 BF – HV MCC#1 supplies power to HS fans, cooling pumps, 3 nos. 2000 kVA, 6.6/0.433 kV
transformers.
 BF – HV MCC#2 supplies power to Main air compressor, CH fume extraction, PCI mill& ID fan
and 3 nos. 1600 kVA, 6.6/0.433 kV transformers.
 SH- HV MCC supplies power to conveyor motors, dedusting motors and 3 nos. 1600 kVA,
6.6/0.433 kV transformers.
Some of the HT motors of HBF are HS fan, Tuyere cooling Pp, Main air compressor, PCI mill, MB-1, 2
etc

There are 11 nos. of transformers for supplying power to different PCCs.

 BF PCC#1 supplies power to Mud gun, BF-BLT, WS, GC, and FF, SGP # 2, EME, TRT and HS
MCC’s.
 BF PCC#2 supplies power to PCI, Dedusting, and BF MCC’s & DB’s.
 SH PCC supplies power to SH-COM, SH MCC’s and DB’s.
 WT PCC supplies power to SGP#1, WT MCC’s and DB.

Emergency MCC’s supplies power to BLT, GC & HS gearbox hydraulic system, Bfce –UPS, battery
charger and emergency lighting. There are 3 nos. of I/C’s including 1050KVA, 415V DG source.
There are lighting DB’s, utility DB’s and PDB’s to supply power to lighting systems, welding, crane and
other miscellaneous utilities.
10% of total lighting system is fed thru emergency feeders.

There are cranes & electrical hoist /chain pulley block for handling of equipments in different areas like
BF Proper, PCI, Blower House, Cast House, TRT, Stock House and Pump House etc.

Earthing system
In order to achieve required earth pit value, earth pits are classified into 3 main heads:
1. Deep bore Earthing( 20 meter and above)
2. Standard Earthing( 3.5m depth)
3. Earthing mat
Depending upon usage earthing system at H Blast furnace is classified into four types which are,
1. NEP(Neutral earth pit)

120
 2. EEP(Equipment earth pit)
3. Electronic earthing
4. Lighting
A global earthing mat, directly buried in ground, is provided, integrated by earth electrodes mainly along
plant area periphery. For electrical building one main earthing ring is provided, buried in ground, along
the building periphery, connected to required number of earth electrodes. Standard earthing station is
provided with 3.5 m long electrode. Deep Bore earthing station is provided with 20, 30 m long electrode
(according to mother soil depth at different location). Earthing ring is interconnected, where possible, with
existing general earthing system. Transformer neutrals are earthed by two separate and distinct earth
connections; each one is taken to an independent earth electrode. From ground connection bars, via
exposed grounding system, earthing connection is provided for metallic equipment. Separate electronic
earthing station is provided.
General layout of Electrical Equipments in Major Buildings

Blast Furnace Load Center (BFLC):

GROUND FLOOR
1. 6 nos. distribution transformers,
2. 6.6kV HV MCC#1,2
3. BF PCC#1,2
8.9M LEVEL
1. MCC- WS#1,2, FF, EME,GC, MUDGUN, CH –DED, BF- BLT, SGP#2,
17.5M LEVEL
1. PLC & Instrument. Room, DCS control room, battery room
2. Office building

Water Treatment Electrical Building:

1. 1600KVA transformer, TR1, 2.
2. WT-PCC
3. MCC- SGP#1, WT, soft starter and VVVF drives
4. DB-WT, LDB and welding DB’s

Stock House Electrical Building:

GROUND FLOOR
1. 3 nos. 1600kVA transformer ,SH-PCC, SH-HV MCC,
2. Welding DB ,lighting DB and lighting transformer
8.5M LEVEL
1. MCC-SH#1,2,COM#1,2,DB-SH
2. DCS control Room

Description of Electrical Equipments

 HT Switch boards
Incomers and Bus couplers
Type= 3AH3, VCB, 12 kV, 2000A, 40kA, 3 sec
Make Siemens
Main Protection: 7SJ63
Motor feeders
Type: 3TL8, Vacuum contactor, 7.2kV, 400A, 8kA, 1 sec
Make: Siemens
Main Protection: AREVA make P220
O/G Transformer feeders:
Type: 3AH3, VCB, 12kV, 1250A, 40kA, 3 sec

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Make: Siemens
Main Protection relay: 7SJ63

Operation Philosophy for I/C and B/C:

HT boards
Two incomers with one bus coupler arrangement is provided. Each incomer is suitable to carry full rated
current of the system. In normal condition both the incomers are ON and B/C is ‘OFF’.
Incomers:
In test position: Closing thru local TNC
In service position: a) Closing from remote **TNC
b) From *TSS switch & **synch. Panel
Bus couplers:
In test position: Closing thru local TNC
In service position: a) Closing from remote TNC
b) From *TSS switch & **synch. Panel
c) ABT (or auto changeover) scheme
Trafo feeder:
In test position: a) Closing thru local TNC
In remote position: b) Remote TNC (RCP)

Motor feeders:
There are 3 positions: a) SWBD mode: in test position from local TNC
b) LPB mode: in service position from LPB at site after getting local permissive
from DCS
c) DCS mode: in service position from DCS

‘* ‘- in B/C panel, ‘**’- in RCP panel

6.6/0.415 kV Distribution Transformers

The 415V PCC is fed from 6.6/0.415 kV Distribution Transformers. There are two sizes i.e 1600KVA and
2000KVA.
Main characteristics are:
• Transformer type: cast resin
• Cooling class: AN
• Winding vector group: Dyn 11
• Installation indoor
• Primary off-load tap changer +- 2 x 2.5 %
• Secondary neutral bushing for earthing
Transformer neutral is solidly earthed through knife switch Isolator.

415 SW boards (PCC)

The 415 V switchboard feeds 415V MCC Boards and main Distribution Boards.
Main characteristics are:
• Degree of protection: IP52
• Symm. Short circuit current 1 sec: 50 kA
• Auxiliary circuits: 110 VAC
• Circuit breakers: motorized ACB
• Single front design, with both front and rear access
Type: C power with SR61C release and CDG 11 relay for E/F (I/C & B/C)
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Make: L&T

Operation Philosophy:
a) 3 incomers and 2 ties with Auto changeovers for BF PCC#1, 2 and
SH-PCC.
(In normal condition 2 incomers are always ON) #
b) 2 incomers and 1 B/C with auto changeover for WT PCC.
(In normal condition both I/Cs are ON and B/C is OFF) # #
# - Min. two I/Cs are required to carry full rated current of system
## - However one I/C is sufficient to carry full rated current of system.

415 V MCC board

The 415 V MCC board feed motors and feeders.
Main characteristics are:
• Degree of protection: IP52
• Symm. Short circuit current 1 sec: 50 kA
• Auxiliary circuits: 110 V ac
• Single front design, with both front and rear access

All process and auxiliary MCC’s, fed from PCC, have double I/C feeders. All air circuit breakers are
electrically operated for remote ON/OFF switches located on wall mounted panels. Incoming Lines and
Tie Breakers are provided with motorised ACB for I>400A, draw-out MCCB for I> 300A up to 400A and
switch isolator for I < 300A.Outgoing feeders for motors are provided with switch-fused Isolator.
Outgoing motor feeders consists of SFU, contactor and overload relay, conforming to type ‘2’ co-
ordination. Outgoing feeders for motors with rating ≥ 110 kW are provided with motor protection relay of
numerical type. Outgoing feeders for motors of rating 37 to 110 kW are provided with microprocessor
based over-current relay (eg MM30), residual earth fault, instantaneous earth fault, stalling and single
phasing protection with current display. Less than 37 kW electronic over-current relay (eg EOCR relay)
are provided. Outgoing feeders for motors of rating ≥ 110 kW are provided with Soft-Starter Unit,
consisting of by-pass contactor, which are mounted in separate panels.

VVVF and Soft Starter Board

For motor feeder P≥110kW Soft Starter is used.
Soft Starter is fed from MCC, installed into a separated board and complete of by-pass arrangement.
Where required by process, VVVF drives are used. These drives fed from MCC, are into a separated
board and don’t have by-pass contactor. For breaking purpose DC injection/dynamic braking (screen
feeders only) is included in drive.

Diesel Generator and Emergency Power Distribution

1 415V Diesel Generator is provided for emergency load supply for Blast Furnace, relevant water system
and for emergency lighting. The emergency MCC receives normal power from the PCC and emergency
power from the DG set so that the loads fed from this emergency MCC (Process load and lighting loads)
will always receive power supply. Auto starting of Diesel Generating set by redundant battery has been
considered in case of supply failure.
Some of the emergency loads supplied are BLT gear box cooling pump, TRT, HS MCC, UPS Bfce etc.

TRT - Top Gas Recovery Turbine

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 TRT is a highly efficient energy saving device for metallurgical industry. It is an energy recovery
unit where BF gas is led to a turbo expander upstream the pressure relieve valve, where BF gas pressure
energy is converted to mechanical energy and to electrical energy via a directly driven generator
The TRT unit will be installed outdoor downstream the annular gap scrubber in parallel with
the bypass valve block. The process flow block diagram of the gas cleaning system shows location of TRT

Gravity dust
catcher

Cyclone
Annular gap DN1800
demister
scrubber

Bypass valve
block TRT

DN2400

Packing
demister

Clean gas
pipework

The new 20MVA, 10kV generator is connected at 33kV level thru 20MVA, 33/10kV kV, ONAN power
transformer. The auxiliaries of TRT generator have LT power supply (415V).

Electrical Blower
There is a provision of 2 dedicated 50% capacity electric blowers. 1 electric blower as stand by for H
or G Fce in emergency has been considered. There is also a provision of air supply from MTM blower
from G fce to H Fce in case of emergency.
The details of synchronous blower motors are
Rated Power : 21.5 MW
Rated Voltage : 2 X 4200
Pf : 0.925
r.pm : 1800
Speed Range : 70 -105%
Efficiency : 97.4 %
Method Cooling : Air To Water H.E
Motor Net Weight : 42 T Approx.
Bearings: Sleeve Bearings, Forced
Oil Lubricated With Vg 46,

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 Fig: Typical Electrical Blower for HBF

The blower motors are fed thru two converter transformers which in turn are connected to Blower
substation at 132kV level. Fig below shows single line diagram for two blower motors.

Fig: SLD showing blower motors of HBF

125
 ANNEXURE- E1
132kV at MPDS#4/PH#6

63/80 MVA, 132/33kV Trafo

63/80 MVA, 132/33kV Trafo

33kV at MPDS#4

33kV at LBSS H Fce

25/31.5 MVA, 20 MVA, 33/10 kV Trafo 25/31.5 MVA,

33/6.6 kV Trafo 33/6.6 kV Trafo
20 MVA TRT
Generator
6.6 kV at LBSS H Fce

6.6 kV BF-HV MCC#1 6.6 kV BF-HV MCC#2 6.6 kV SH MCC

6.6 kV WT PCC
415 V BF- PCC-1

Fig: Single Line Diagram of H Blast Furnace

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12.2 Automation & Instrumentation

AUTOMATION SYSTEM

Automation system at H Blast Furnace comprises of ABB 800xA Distributed Control System. The
following functions and features are addressed by the DCS system:

FUNCTIONS
- Facilitating Plant operation and monitoring
- Dynamic interactive graphic display, group displays, loop displays
- Real time trends and historical trends
- Process alarm and event monitoring
- Diagnostic alarm and events monitoring
- Connectivity with CCTV and Public Address system (for event/alarm based broadcasting)
- Condition monitoring of critical equipment
- Data logging and on-line configurable report generation with time stamping

H/W & S/W FEATURES

- Multi-level password system for operators, maintenance people and engineers.
- Third party intelligent system interface
- Redundant server human machine interface
- Real time server data base
- Bump less transfer among redundant components without any loss of data
- Online changing of I/O modules (hot swapping)
- I/O module fault reported to processors
- Analog modules comprehensive self-diagnostic tests : open-input / open-loop detection
- Maintenance related information like pump/fan runtime etc. and alarm on reaching value
- Facility for remote training, trouble shouting, software upgrade
- Alarm signal from UPS at battery low voltage condition

SYSTEM ARCHITECTURE

Level-1 Automation system will monitor and control all significant variables in accordance with the
process requirements, provide operating requirements and necessary sequencing, interlocking and safety
functions including alarms for abnormal conditions. The Level-1 automation system will be designed as
an integrated system for drives control and instrumentation The system includes DCS control stations, PC
based engineering/operator stations as HMI units, redundant data communication bus, Distributed I/O
units, printers and interface with Level-2 Automation system.

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Basic architecture of Level-1 Automation system

SYSTEM CONFIGURATION DRAWING

MAIN CONTROL ROOM LEVEL 1 AUTOMATION
CCTV NETWORK
LARGE SCREEN DISPLAY

TRT CONTROL PCI CONTROL SH & RMHS CONTROL ROOM

ROOM ROOM
SERVER
FOR
EXTERNAL
CONNECT-
-IVITY

REDUNDANT REDUNDANT
SERVER CUM SERVER CUM
ENGINEER- ENGINEER-
-ING -ING
SATION SATION

HISTORY REDUNDANT ASPECT

SERVER SERVER

CH & FES UTILITY DM PLANT COAL INECTION INBA 2 GCP BF & TOP RECOVERY TURBINE COAL PREPARATION SH -1 SH -2 SH DEDUSTING2 SH FINES
MEASUREMENTS
CONTROLLERS

WASTE WATER
INBA 1 TREATMENT

ETHERNET
STOVES 1 STOVES 2 TCP/IP
COOLING COOLING BLT PROBES & CH 1 CH 2 WT & CH DEDUSTING
UTILITY STOVES DCS ROOM
DCS ROOM

CONTROLLERS

DUAL PROCESSOR CONTROLLER CH & FES: CAST HOUSE & FUME EXTRACTION SYSTEM

DM PLANT: DE-MINERALIZED PLANT

INBA: ITALIAN ABBREVIATION (INDICATING SGP – SLAG GRANULATION PLANT)

SERVER
GCP: GAS CLEANING PLANT

BF: BLAST FURNACE

SH: STOCK HOUSE

OPERATOR STATION BLT: BELL LESS TOP

WT: WATER TREATMENT

DCS: DISTRIBUTED CONTROL SYSTEM

LARGE SCREEN DISPLAY
TRT: TOP GAS RECOVERY TURBINE

RMHS: RAW MATERIAL HANDLING SYSTEM

PRINTER
PCI: PULVERIZED COAL INJECTION

CCTV: CLOSE CIRCUIT TELE-VISION

LEGEND

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INSTRUMENTATION SYSTEM
The instrumentation system facilitates in measurement and control of following processes in H Blast
Furnace:

 Level of Hot Metal in Torpedo Ladle Car using radar has been considered.

 Slag flow measurement will be done by belt weighing system in SGP. Wet slag measurement in
cast house will not be done. System is designed in order that quantity of granulated slag thus
measured will be approximately 100% of wet slag tapped in cast house (Dry pit is only for
emergency)
 Hot metal temperature measuring system using Infrared Pyrometer as well as Dip-type
measurement has been considered.
 Stove Dome temperature measuring system envisaged using Infrared Pyrometer as well as
thermocouple.
 Hot Blast temperature measuring system using Infrared Pyrometer as well as thermocouple.

 Burden Profilometer is used to assess the profile of the burden inside Blast Furnace.

 Top gases Hydrogen, Carbon monoxide, Carbon Dioxide are measured through gas-analyzers.

 Stove flue Gas oxygen and CO are analyzed with respective gas analyzers.

 Ultrasonic type bin level measurement is used to measure the level of bins with two numbers for
each bin.
 Cold Blast Humidity measurement is done with moisture analyzer.

 Stove Flame detector is used to detect the status of burner flame for process control.

 Coke moisture measurement is done through nucleonic gauges.

 Thermocouples at various stages in hearth of blast furnace are provided to assess the profile of
hearth temperature as well as assessing status of copper staves cooling system. In other parts of the
furnace and other associated processes / equipments the temperature sensing is done through
thermocouples as well as RTDs.
 One Nos. stock rod and two Nos. radar type stock level measurements are used to measure the
stock level inside the furnace.
 Dust content monitor at stacks of Cast house Fume extraction system and Stock house De-dusting
system are used.
 SOx and NOx Analyzer systems for stove flue gas.

 Portable CO monitors and wall mounted CO monitors are used for detection of CO.

 Calorific value analysis for fuel gas (BF gas and LD gas) to Stoves will be done by Software
calculation based on CO and H2 analyzer data of Top Gas and LD gas.

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 Two (2) Nos. radar type sensors will be provided at the Furnace top side end of main charging
conveyor. One sensor at approx. 20 m from furnace top will initiate depressurization of BLT
hopper and the second sensor at approx. 5m form furnace top will trip the conveyor if upper seal
valve is not open.
 I/P converters for all pneumatic control valves are used.

 Under Burden Probes and Above Burden Probes facilitates the operator to know about the
temperature of the burden under and above of the burden inside the Blast furnace respectively.
 Belt Weighing System is used at various places in various places in the plant where record for
material being transferred need to be recorded.
 Hopper weighing System has been provided at weigh bins at Stock House and hoppers of Bell
Less Top System to facilitate weighing of material being processed as an essential part of the
process.
 Radio Control System for Cast House Operation has been envisaged in view of Safety &
Environment.
 CCTV Monitoring & Control System is used for visual monitoring of condition of various
strategic points in the process plant. 28 numbers of cameras will be used to capture information
and will be displayed in monitors (10nos.) at various control rooms on selection basis.
 Public Addressing System & Walky–Talky System will be in use for addressing the
communication requirement at various places during normal and emergency situations arising in
the plant.
 Level 2 Automation System will be used for providing various Expert Level Management
Information Systems and Models to facilitate better visualization / monitoring and optionally to
control the plant health in a better manner.
 Un-interrupted Power Supply (UPS) has been used to provide supply to all the controllers and
important equipments.
 VVVF Drive System has been considered at all the places where precise motorized control is
required.
 Fire Alarm & Control System is considered for the fire protection all control rooms.

 Remote Control for Cranes Operation is considered for operating EOT Cranes.

 Large Screen Display (2 nos.) have been considered in the Main Control Room for larger view of
the screen on selection basis.
 Siemens PLC for Cast House has been considered as an integral part of the equipment.

 Soft Starter for Motors of rating > 100 KW has been envisaged.

 Vibration Monitoring for all HT Motors has been considered as condition monitoring equipment.

 Magnetic Flow Meters have been considered at various places to detect the flow of the water for
assessing the adequacy of cooling system as well as detection of leakages in the system.
 Utility requirement of HP / LP Steam, HP / LP Nitrogen, HP / LP Oxygen, Water, LD Gas, BF Gas,
CO Gas, Air has been considered for various application and the respective control valves / control
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& monitoring equipments have been designed to monitor and control these items within desired
limits.

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