{"id":5751,"date":"2017-12-07T22:04:19","date_gmt":"2017-12-07T20:04:19","guid":{"rendered":"http:\/\/www.mtechnology.com.ua\/?p=5751"},"modified":"2023-02-16T20:23:53","modified_gmt":"2023-02-16T18:23:53","slug":"blast-furnace-repairs","status":"publish","type":"post","link":"https:\/\/mtechnology.com.ua\/en\/blast-furnace-repairs\/","title":{"rendered":"Blast furnace repairs"},"content":{"rendered":"\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-av_one_full-6126cab7d8fab8d08143dd2dacdf673c\">\n.flex_column.av-av_one_full-6126cab7d8fab8d08143dd2dacdf673c{\nborder-radius:0px 0px 0px 0px;\npadding:0px 0px 0px 0px;\n}\n<\/style>\n<div  class='flex_column av-av_one_full-6126cab7d8fab8d08143dd2dacdf673c av_one_full  avia-builder-el-0  el_before_av_textblock  avia-builder-el-first  first flex_column_div av-zero-column-padding  '     ><p><section  class='av_textblock_section av-av_textblock-0366cc7376be6c9e82a3e9cc8987b64f '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p>Throughout the past 3 years \u00abM Technology\u00bb has participated in over than 30 blast furnace reconstruction projects.<br \/>\n<!--more--><\/p>\n<p>Over a dozen of projects were focused on solving one of the most challenging issues of the modern blast furnace process \u2013 significant decrease of operating time of standard cooling systems (with the use of untreated water), and subsequently &#8211; a fast failure of the cooling staves under the condition of pulverized coal injection.<br \/>\nThe efficiency of the cooling system today determines the period of the blast furnace campaign, that is why modern cooling systems are faced with increased requirements to ensure reliability and high operation availability.<br \/>\nWhat do we understand by a modern cooling system and what are the requirements to it today? The cooling system should provide the following under\u00a0 the conditions of PC injection:<\/p>\n<p>\u2014 efficient heat removal from cooling staves and lining;<br \/>\n\u2014 formation and maintenance of a stable skull layer on the lining surface;<br \/>\n\u2014 energy efficiency, reduction of heat losses with the use of the cooling system, saving expensive coke;<br \/>\n\u2014 reduction of the environmental impact by using closed-loop (zero-discharge) cooling systems or load decrease on the enterprise&#8217;s recirculation system;<br \/>\n\u2014 extension of the BF campaign up to 15 years.<\/p>\n<p>Using an innovative approach to solving this problem,\u00a0 modern calculation systems and three-dimensional modeling, &#8220;M TECHNOLOGY&#8221; LLC has developed a number of measures that have been successfully implemented at\u00a0 many blast furnaces.<br \/>\nAfter implementation of the facilities\u00a0 our company experts monitor the the cooling systems work over the entire\u00a0 period of the facility operation.<\/p>\n<p>By collecting data on the progress of work, taking into account the experience of the operating personnel, we are constantly improving the decisions made.<\/p>\n<p>We are proud that METINVEST HOLDING has used &#8220;M TECHNOLOGY&#8221; proprietary system of cooling intensity regulation as a standard solution for revamping and construction of new\u00a0 blast furnaces.<\/p>\n<p>Among the projects described above, the following ones can be underscored:<\/p>\n<p>BF No. 2, BF No. 3, BF No. 4, BF No. 5 of PJSC &#8220;Zaporizhstal&#8221;, BF No. 3, BF No. 4 and BF No. 6 at PJSC &#8220;Azovstal&#8221;, BF\u00a0 No. 4 of PJSC &#8221; Ilyich Iron and Steel Works &#8220;, BF\u00a0 \u21165 of PJSC&#8221; EMZ&#8221;.<\/p>\n<p style=\"text-align: center;\"><strong>BF \u21162 PJSC &#8220;Zaporizhstal&#8221;<\/strong><\/p>\n<\/div><\/section><br \/>\n\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-av_image-ebbe9fbd82951d7100c85227dd0d878e\">\n.avia-image-container.av-av_image-ebbe9fbd82951d7100c85227dd0d878e img.avia_image{\nbox-shadow:none;\n}\n.avia-image-container.av-av_image-ebbe9fbd82951d7100c85227dd0d878e .av-image-caption-overlay-center{\ncolor:#ffffff;\n}\n<\/style>\n<div  class='avia-image-container av-av_image-ebbe9fbd82951d7100c85227dd0d878e av-styling- avia-align-center  avia-builder-el-2  el_after_av_textblock  el_before_av_textblock '   itemprop=\"image\" itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/ImageObject\" ><div class=\"avia-image-container-inner\"><div class=\"avia-image-overlay-wrap\"><img fetchpriority=\"high\" class='wp-image-4453 avia-img-lazy-loading-not-4453 avia_image ' src='https:\/\/mtechnology.com.ua\/wp-content\/uploads\/2017\/12\/1.png' alt='' title='1'  height=\"408\" width=\"661\"  itemprop=\"thumbnailUrl\"  \/><\/div><\/div><\/div><br \/>\n<section  class='av_textblock_section av-av_textblock-0366cc7376be6c9e82a3e9cc8987b64f '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p>At Zaporizhstal PJSC BF No.2 it was our company to apply solutions that effectively deal with the negative impact of the pulverized coal injection on blast furnace campaign duration and its energy efficiency.<br \/>\n&#8211; Our company performed the following scope of works:<br \/>\n\u2014 we were the pioneers to apply an automatic cooling system with the cooling rate control depending on the heat load inside the blast furnace. It was cooling with hot demineralized water, where heat was removed from heated water not through heat exchangers, but by removing steam from a separator drum. This cooling system has 3 operation modes: closed loop cooling with &#8220;hot&#8221; demineralized water, evaporative cooling with natural circulation, industrial water backup;<br \/>\n&#8211; \u2014 first ever in Ukraine, copper cooling staves have been installed in the second and third rows of the BF stack. The blast furnace lintel-type design made it difficult to install the copper staves in the bosh. Later on we have found a solution for lintel-type BF #5 at PJSC \u201cEMZ\u201d, but this project has been never implemented due to \u201cEMZ\u201d secession from METINVEST HOLDING;<br \/>\n\u2014highly heat-conductive thick-walled lining was applied at this blast furnace: (in the bosh and 3 stack rows it was made of silicon carbide, above them it was alumina-carbon and chamotte);<br \/>\n\u2014 a new pumping station with electric pump units and frequency-controlled engine speed was built;<br \/>\n\u2014 a modern Automatic Process Control System was installed.<br \/>\nAll above-listed solutions have allowed to prevent the staves from burn-outs and to enormously reduce heat losses from the furnace, resulting in reduction of coke consumption.<br \/>\nCombined application of copper staves, highly heat-conductive lining and automatic cooling system provided formation and maintaining a stable skull layer on the lining surface, but not on the staves, which made possible reliable BF operation and extended the BF campaign.<br \/>\nBasic diagram of the \u201chot\u201d demineralized water cooling of BF No. 2:<\/p>\n<\/div><\/section><br \/>\n\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-av_image-16767eb1031806d5cab3746b7be3d3bb\">\n.avia-image-container.av-av_image-16767eb1031806d5cab3746b7be3d3bb img.avia_image{\nbox-shadow:none;\n}\n.avia-image-container.av-av_image-16767eb1031806d5cab3746b7be3d3bb .av-image-caption-overlay-center{\ncolor:#ffffff;\n}\n<\/style>\n<div  class='avia-image-container av-av_image-16767eb1031806d5cab3746b7be3d3bb av-styling- avia-align-center  avia-builder-el-4  el_after_av_textblock  el_before_av_textblock '   itemprop=\"image\" itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/ImageObject\" ><div class=\"avia-image-container-inner\"><div class=\"avia-image-overlay-wrap\"><img fetchpriority=\"high\" class='wp-image-4455 avia-img-lazy-loading-not-4455 avia_image ' src='https:\/\/mtechnology.com.ua\/wp-content\/uploads\/2017\/12\/2.png' alt='' title='2'  height=\"829\" width=\"661\"  itemprop=\"thumbnailUrl\"  \/><\/div><\/div><\/div><br \/>\n<section  class='av_textblock_section av-av_textblock-0366cc7376be6c9e82a3e9cc8987b64f '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p style=\"text-align: center;\"><strong>BF\u21164 PJSC \u00abZaporizhstal\u00bb<\/strong><\/p>\n<p>The scope of our work related to the BF repair, as well as the solutions taken, were similar to BF No.2 repair, but they had several distinctive features:<br \/>\n\u2014 copper cooling staves were installed in the belly zone and two bottom rows of the stack, but the BF lintel-type design made installation of copper cooling staves in the bosh area challenging, so cast iron cooling plates were left in that zone;<br \/>\n\u2014 pre-lined cooling staves were first used at this BF (silicon carbide firebricks were inserted into the copper stave prior to installation, the bricks and the staves were dovetailed). This solution allowed to reduce erection time, eliminated the risk of the entire brickwork falling as a result of local destruction, enhanced fixation and contact area of silicon carbide with the stave wall, which significantly increased the heat transfer from the stave to the brickwork, resulting in an effective lining protection and maintaining a stable skull layer.<\/p>\n<p>Copper cooling staves with silicon carbide brick pre-lining:<\/p>\n<\/div><\/section><br \/>\n\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-av_image-cfe62345da72dbe87c27b5b3b03e3a23\">\n.avia-image-container.av-av_image-cfe62345da72dbe87c27b5b3b03e3a23 img.avia_image{\nbox-shadow:none;\n}\n.avia-image-container.av-av_image-cfe62345da72dbe87c27b5b3b03e3a23 .av-image-caption-overlay-center{\ncolor:#ffffff;\n}\n<\/style>\n<div  class='avia-image-container av-av_image-cfe62345da72dbe87c27b5b3b03e3a23 av-styling- avia-align-center  avia-builder-el-6  el_after_av_textblock  avia-builder-el-last '   itemprop=\"image\" itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/ImageObject\" ><div class=\"avia-image-container-inner\"><div class=\"avia-image-overlay-wrap\"><img fetchpriority=\"high\" class='wp-image-4457 avia-img-lazy-loading-not-4457 avia_image ' src='https:\/\/mtechnology.com.ua\/wp-content\/uploads\/2017\/12\/3.png' alt='' title='3'  height=\"495\" width=\"661\"  itemprop=\"thumbnailUrl\"  \/><\/div><\/div><\/div><\/p><\/div><section  class='av_textblock_section av-av_textblock-0366cc7376be6c9e82a3e9cc8987b64f '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p style=\"text-align: center;\"><strong>BF \u21162 and BF \u21164 PJSC \u00abZaporizhstal\u00bb<\/strong><\/p>\n<p>The enterprise intended to increase the pulverized coal injection into the BF hearths and to achieve performance of 180 \u00f7 200 kg\/t-HM. Therefore it was decided to change-over BF No.2 and BF No. 4 cooling system to &#8220;cold&#8221; demineralized water closed-loop cooling.<br \/>\nFor this purpose our company has developed a project for installation of plate heat exchangers, water\/water type, at these blast furnaces, aimed to decrease the cooling water temperature up to 35 \u00f7 45\u00b0C. A technology of service water flow control depending on season temperature fluctuations and heat load inside the blast furnace was applied in all heat exchangers. This solution allowed up to 50% service water saving in winter time.<br \/>\nAfter the project implementation the blast furnaces can be operated with 4 independent cooling modes:<br \/>\n\u2014 cooling with &#8220;cold&#8221; demineralized water;<br \/>\n\u2014 cooling with &#8220;hot&#8221; demineralized water;<br \/>\n\u2014 evaporative cooling with natural circulation;<br \/>\n\u2014 standby cooling with technical water.<br \/>\nBasic diagram of the \u201ccold\u201d demineralized water cooling:<\/p>\n<\/div><\/section><\/p>\n\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-av_image-e678165e95753fffefbf6dd24c46bdca\">\n.avia-image-container.av-av_image-e678165e95753fffefbf6dd24c46bdca img.avia_image{\nbox-shadow:none;\n}\n.avia-image-container.av-av_image-e678165e95753fffefbf6dd24c46bdca .av-image-caption-overlay-center{\ncolor:#ffffff;\n}\n<\/style>\n<div  class='avia-image-container av-av_image-e678165e95753fffefbf6dd24c46bdca av-styling- avia-align-center  avia-builder-el-8  el_after_av_textblock  el_before_av_textblock '   itemprop=\"image\" itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/ImageObject\" ><div class=\"avia-image-container-inner\"><div class=\"avia-image-overlay-wrap\"><img fetchpriority=\"high\" class='wp-image-4439 avia-img-lazy-loading-not-4439 avia_image ' src='https:\/\/mtechnology.com.ua\/wp-content\/uploads\/2017\/12\/4.png' alt='' title='4'  height=\"810\" width=\"661\"  itemprop=\"thumbnailUrl\"  \/><\/div><\/div><\/div>\n<section  class='av_textblock_section av-av_textblock-0366cc7376be6c9e82a3e9cc8987b64f '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p style=\"text-align: center;\"><strong>BF \u21165 PJSC \u00ab<\/strong><strong>Zaporizhstal\u00bb<\/strong><\/p>\n<\/div><\/section>\n\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-av_image-d6f0f7785f202db08f53dcb06a005d73\">\n.avia-image-container.av-av_image-d6f0f7785f202db08f53dcb06a005d73 img.avia_image{\nbox-shadow:none;\n}\n.avia-image-container.av-av_image-d6f0f7785f202db08f53dcb06a005d73 .av-image-caption-overlay-center{\ncolor:#ffffff;\n}\n<\/style>\n<div  class='avia-image-container av-av_image-d6f0f7785f202db08f53dcb06a005d73 av-styling- avia-align-center  avia-builder-el-10  el_after_av_textblock  el_before_av_textblock '   itemprop=\"image\" itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/ImageObject\" ><div class=\"avia-image-container-inner\"><div class=\"avia-image-overlay-wrap\"><img fetchpriority=\"high\" class='wp-image-4441 avia-img-lazy-loading-not-4441 avia_image ' src='https:\/\/mtechnology.com.ua\/wp-content\/uploads\/2017\/12\/5.png' alt='' title='5'  height=\"396\" width=\"661\"  itemprop=\"thumbnailUrl\"  \/><\/div><\/div><\/div>\n<section  class='av_textblock_section av-av_textblock-0366cc7376be6c9e82a3e9cc8987b64f '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p>During the project execution an automatic cooling system by means of &#8220;cold&#8221; demineralized water in a closed loop with construction of a new pumping station and a room for plate heat exchangers, water\/water type, was implemented.<br \/>\nIt was decided to install steel cooling staves, pre-lined with silicon carbide bricks, in the peak heat load areas (bosh, belly and stack rows 1 \u2013 3). Steel staves are an alternative to copper cooling staves, they provide a reliable heat dissipation and ensure efficient cooling of the lining. The main feature of the steel cooling staves is no boundary between the cast-in pipe and the stave body. The cast steel stave material is low-carbon steel with 0.2 to 0.3% carbon content.<br \/>\nIt was the first blast furnace in the post-Soviet space, equipped with steel cooling staves.<br \/>\nSteel cooling staves with silicon carbide pre-lining:<\/p>\n<\/div><\/section>\n\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-av_image-b28e8b17662c7ceb7f6a11afb6f31daf\">\n.avia-image-container.av-av_image-b28e8b17662c7ceb7f6a11afb6f31daf img.avia_image{\nbox-shadow:none;\n}\n.avia-image-container.av-av_image-b28e8b17662c7ceb7f6a11afb6f31daf .av-image-caption-overlay-center{\ncolor:#ffffff;\n}\n<\/style>\n<div  class='avia-image-container av-av_image-b28e8b17662c7ceb7f6a11afb6f31daf av-styling- avia-align-center  avia-builder-el-12  el_after_av_textblock  el_before_av_textblock '   itemprop=\"image\" itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/ImageObject\" ><div class=\"avia-image-container-inner\"><div class=\"avia-image-overlay-wrap\"><img fetchpriority=\"high\" class='wp-image-4443 avia-img-lazy-loading-not-4443 avia_image ' src='https:\/\/mtechnology.com.ua\/wp-content\/uploads\/2017\/12\/6.png' alt='' title='6'  height=\"150\" width=\"661\"  itemprop=\"thumbnailUrl\"  \/><\/div><\/div><\/div>\n<section  class='av_textblock_section av-av_textblock-0366cc7376be6c9e82a3e9cc8987b64f '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p style=\"text-align: center;\"><strong>BF \u21163 PJSC\u00ab<\/strong><strong>Zaporizhstal\u00bb<\/strong><\/p>\n<\/div><\/section>\n\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-av_image-80f1ef2fbaf92135152a24bec6467a28\">\n.avia-image-container.av-av_image-80f1ef2fbaf92135152a24bec6467a28 img.avia_image{\nbox-shadow:none;\n}\n.avia-image-container.av-av_image-80f1ef2fbaf92135152a24bec6467a28 .av-image-caption-overlay-center{\ncolor:#ffffff;\n}\n<\/style>\n<div  class='avia-image-container av-av_image-80f1ef2fbaf92135152a24bec6467a28 av-styling- avia-align-center  avia-builder-el-14  el_after_av_textblock  el_before_av_textblock '   itemprop=\"image\" itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/ImageObject\" ><div class=\"avia-image-container-inner\"><div class=\"avia-image-overlay-wrap\"><img fetchpriority=\"high\" class='wp-image-4445 avia-img-lazy-loading-not-4445 avia_image ' src='https:\/\/mtechnology.com.ua\/wp-content\/uploads\/2017\/12\/7.png' alt='' title='7'  height=\"440\" width=\"661\"  itemprop=\"thumbnailUrl\"  \/><\/div><\/div><\/div>\n<section  class='av_textblock_section av-av_textblock-0366cc7376be6c9e82a3e9cc8987b64f '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p>Pulverized coal injection into the furnace hearth (PCI was put in operation in 2011) led to considerable increase of the thermal load on the cooling system, especially in stressed areas, which resulted in stave damages, BF shell overheating, as well as shell cracks and deformations.<br \/>\nFor this reason it was decided to dismantle the blast furnace and to build a new one with the same volume of Vn = 1513 m\u00b3 in the same place but on a new foundation.<br \/>\nBF cooling is performed both with technical water and demineralized water in a closed loop.<br \/>\nProcess water is used for cooling the furnace bottom, bottom staves, hearth staves, upper stack and top staves, while the bosh, belly, lower and middle stack staves as well as the tap-hole staves are cooled with demineralized water.<br \/>\nDue to high thermal loads on the cooling system, typical for operation with PCI, the furnace is equipped with copper staves in the bosh, belly and lower stack.<br \/>\nIn addition, copper staves are installed around the hot metal tapholes. The solution is first ever implemented on the territory of Ukraine, precisely in the framework of this project.<br \/>\nThe rest of the staves are traditional cast-iron plate staves.<br \/>\nBoth copper and cast-iron staves of the stack have dovetail joints for firebrick installation. Refractory lining is produced by Gongyi AR Co. (China).<br \/>\nThe lower part of the furnace is presented with one row of graphitized blocks (production of \u201cUkrgraphite\u201d, Ukraine), four rows of microporous carbon blocks covered with a ceramic cup. Peripheral blocks are carbon microporous and supermicroporous carbon blocks covered with a ceramic cup. The tuyer zone is lined with sialon-bonded silicon carbide refractory bricks.<br \/>\nThe bosh, belly, lower and middle stack are lined with silicon carbide bricks, the stack upper part and the top \u2013 with fireclay bricks.<br \/>\nCarbon concrete and silicon carbide concrete are used for filling the space between the BF metal bottom and water cooling pipes.<br \/>\nThe gap between the staves and peripheral blocks is filled with cold ramming mass of increased thermal conductivity.<br \/>\nThe space between the furnace shell and the staves is filled with unshrinkable mass with low thermal conductivity.<\/p>\n<p>Installation of the hearth and hearth bottom staves:<\/p>\n<\/div><\/section>\n\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-av_image-0d2ca51362d0f95ab7274815d65e0f0b\">\n.avia-image-container.av-av_image-0d2ca51362d0f95ab7274815d65e0f0b img.avia_image{\nbox-shadow:none;\n}\n.avia-image-container.av-av_image-0d2ca51362d0f95ab7274815d65e0f0b .av-image-caption-overlay-center{\ncolor:#ffffff;\n}\n<\/style>\n<div  class='avia-image-container av-av_image-0d2ca51362d0f95ab7274815d65e0f0b av-styling- avia-align-center  avia-builder-el-16  el_after_av_textblock  el_before_av_textblock '   itemprop=\"image\" itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/ImageObject\" ><div class=\"avia-image-container-inner\"><div class=\"avia-image-overlay-wrap\"><img fetchpriority=\"high\" class='wp-image-4447 avia-img-lazy-loading-not-4447 avia_image ' src='https:\/\/mtechnology.com.ua\/wp-content\/uploads\/2017\/12\/8.png' alt='' title='8'  height=\"371\" width=\"661\"  itemprop=\"thumbnailUrl\"  \/><\/div><\/div><\/div>\n<section  class='av_textblock_section av-av_textblock-0366cc7376be6c9e82a3e9cc8987b64f '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p style=\"text-align: center;\"><strong>BF \u21165 PJSC \u00ab\u0415MZ\u00bb<\/strong><\/p>\n<p style=\"text-align: left;\">The following works have been performed under the scope of this project:<br \/>\n\u2014 construction of a new pumping station with installation of pumps and heat exchangers in the amount needed to provide stable operation of the cooling system taking into consideration standby pumps and heat exchangers as well as redundancy<br \/>\n\u2014 installation and connection of instrumentation (water flow, pressure and temperature sensors) with the signal transfer to the room of the pipemen on duty and to the workstations of BF No.5 water treatment plant engineers;<br \/>\n\u2014 BF stack thermocouple installation and connection to the instruments;<br \/>\n\u2014 connection of the pumping station switchgear from 1600 kVa transformers of the 4\u0422\u041f5\u0414 substation;<br \/>\n&#8211; \u2014 the 4\u0422\u041f5\u0414 power switchboard modernization with installation of additional switching devices;<br \/>\n\u2014 ALT is provided in the switchgear of the designed pumping station both for power supply and for standby units activation;<br \/>\n\u2014 automatic process control system:<br \/>\n\u0430) pumping units, heat exchanger ventilators control via Ethernet;<br \/>\nb) DLR network technology to improve the system reliability and fault tolerance;<br \/>\nc) modular replacement of the controller equipment without control interruption;<br \/>\nd) diagnostics of the system equipment and the closed loop connected to PLC;<br \/>\ne) subsystem for the BF No.5 shell temperature display;<br \/>\nf) integrated vibration monitoring of the pump units via Ethernet;<br \/>\n\u2014 replacement of cast-iron staves of the bosh and 4 rows of the furnace stack with copper staves (the copper staves are designed with consideration of the furnace profile; the staves are interconnected with flexible metal hoses);<br \/>\n\u2014 automatic stack lining erosion control of BFNo.5;<br \/>\n\u2014 application of a high-conductive silicon carbide lining for the bosh, belly and BF stack.<br \/>\nA pioneer solution of the copper staves installation at a lintel-type furnace both in the bosh and in the lower rows of the stack was implemented at this furnace.<\/p>\n<\/div><\/section>\n\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-av_image-aced8690bedd35ca1bf6804663c584ef\">\n.avia-image-container.av-av_image-aced8690bedd35ca1bf6804663c584ef img.avia_image{\nbox-shadow:none;\n}\n.avia-image-container.av-av_image-aced8690bedd35ca1bf6804663c584ef .av-image-caption-overlay-center{\ncolor:#ffffff;\n}\n<\/style>\n<div  class='avia-image-container av-av_image-aced8690bedd35ca1bf6804663c584ef av-styling- avia-align-center  avia-builder-el-18  el_after_av_textblock  el_before_av_textblock '   itemprop=\"image\" itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/ImageObject\" ><div class=\"avia-image-container-inner\"><div class=\"avia-image-overlay-wrap\"><img fetchpriority=\"high\" class='wp-image-4449 avia-img-lazy-loading-not-4449 avia_image ' src='https:\/\/mtechnology.com.ua\/wp-content\/uploads\/2017\/12\/9.png' alt='' title='9'  height=\"766\" width=\"661\"  itemprop=\"thumbnailUrl\"  \/><\/div><\/div><\/div>\n<section  class='av_textblock_section av-av_textblock-0366cc7376be6c9e82a3e9cc8987b64f '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p style=\"text-align: center;\"><strong>BF \u21163 PJSC \u00ab\u0410zovstal Iron and Steel Works\u00bb<\/strong><\/p>\n<\/div><\/section>\n\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-av_image-e1c19852b6e1193778b74002f60963fe\">\n.avia-image-container.av-av_image-e1c19852b6e1193778b74002f60963fe img.avia_image{\nbox-shadow:none;\n}\n.avia-image-container.av-av_image-e1c19852b6e1193778b74002f60963fe .av-image-caption-overlay-center{\ncolor:#ffffff;\n}\n<\/style>\n<div  class='avia-image-container av-av_image-e1c19852b6e1193778b74002f60963fe av-styling- avia-align-center  avia-builder-el-20  el_after_av_textblock  el_before_av_textblock '   itemprop=\"image\" itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/ImageObject\" ><div class=\"avia-image-container-inner\"><div class=\"avia-image-overlay-wrap\"><img fetchpriority=\"high\" class='wp-image-4393 avia-img-lazy-loading-not-4393 avia_image ' src='https:\/\/mtechnology.com.ua\/wp-content\/uploads\/2017\/04\/\u0410\u0437\u043e\u0432\u0441\u0442\u0430\u043b\u044c_\u0414\u041f3_5-min-1030x579.jpg' alt='' title='\u0410\u0437\u043e\u0432\u0441\u0442\u0430\u043b\u044c_\u0414\u041f3_5-min'  height=\"579\" width=\"1030\"  itemprop=\"thumbnailUrl\"  \/><\/div><\/div><\/div>\n<section  class='av_textblock_section av-av_textblock-0366cc7376be6c9e82a3e9cc8987b64f '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p>In the scope of the project the existing shell was replaced with a shell of a self-supporting design, made of modern wear- and heat-resistant materials, with consideration of max 2.0 atm top pressure.<br \/>\nIn fact, a new blast furnace was constructed on the existing foundation where the top ring elevation and the HM taphole axes elevation remained unchanged.<br \/>\nThe furnace profile was designed with taking into account pulverized coal injection.<br \/>\nThe new BFNo.3 profile is characterized by the following features: the bosh height increased, the belly height decreased, the belly\/hearth diameter ratio increased; the top, belly and hearth diameters increased. The stack inclination angle remained unchanged and the bosh angle decreased.<\/p>\n<p>The lining of the furnace bottom central part from el. +2,500 was performed as follows:<br \/>\n\u2014 the base row is made of graphitized blocks, H = 400 mm;<br \/>\n\u2014 four rows of low-porous carbon blocks with the total height of 2,000 mm above;<br \/>\n\u2014 one row of microporous carbon blocks, H = 500 mm, above;<br \/>\n\u2014 two rows of high-alumina refractories with the height of 1,000 mm up to el. +6,400.<br \/>\nThe lining of the hearth walls from el. +4,900 to +10,200 is made of microporous carbon blocks. The hearth working surface is protected with a 400-mm thick ceramic cup.<br \/>\nThe lining of the tuyer zone is made of compound aluminium-carborundum refractory blocks shaped correspondingly to the tuyer stock elements, which results in reducing the number of joints between the refractory elements and increasing the lifetime of the lining in the tuyer zone.<br \/>\nThe bosh and stack lining is made of refractory bricks:<br \/>\n\u2014 the bosh is lined with silicon carbide bricks;<br \/>\n\u2014 the belly and the lower stack lining is made of 150-mm silicon carbide bricks (the bricks are dovetailed into the staves) and a hydraulic bonded silicon carbide gunite coating;<br \/>\n\u2014the middle stack consists of microporous alumina-carbon bricks;<br \/>\n\u2014 the upper stack \u2013 fireclay bricks.<br \/>\nThe top is lined with protective water-cooled plates with cast-in fireclay bricks.<br \/>\nThe space between the blast furnace shell and the cooling staves is filled with special high-flowable refractory mixture, which ensures high gas tightness of the furnace and shell insulation.<br \/>\nThe furnace cone is lined with gunite and steel lining plates. The gaps between the lining plates are rammed in with cast-iron sealing compound.<br \/>\nThe furnace cooling is performed with closed-loop demineralized water.<br \/>\nThe following works have been carried out for the system implementation:<br \/>\n\u2014 construction of a new demineralized water circulation pump station, including installation of pumps and heat exchangers in the amount needed for the stable cooling system operation with taking into account standby pumps and heat exchangers as well as redundancy in case of power cutoffs;<br \/>\n\u2014 construction of a new filter station for sea water;<br \/>\n\u2014 implementation of the automatic staves cooling rate control system<br \/>\n(\u041c TECHNOLOGY patent No. 105036);<br \/>\n\u2014 construction of an external and internal pipeline with installation of shut-off, safety and control valves;<br \/>\n\u2014 installation of copper staves in the bosh zone, belly as well as in the 1st and 2nd stack rows;<br \/>\n\u2014 installation of one row of steel staves (3rd stack row;<br \/>\n\u2014 installation of copper staves in the HM tapholes zone.<br \/>\nThe staves are designed as follows:<br \/>\nthe lower part of the furnace (bottom, hearth and tuyer zone) up to el. +13,650 are smooth cast-iron cooling staves. The staves are made of cast-iron grade \u0421\u0427 15-32 GOST 1412-85, cooling pipes are steel &#8220;pipe coils&#8221;, \u00d8 70\u00d78 mm; the staves around the HM tapholes and 7 staves under the tapholes are copper plates with drilled channels \u00d8 50 mm.<br \/>\nCopper staves with drilled channels Deq = 50 mm are installed in the peak thermal load area (two rows of the bosh, one row of the belly and two rows of the stack).<br \/>\nThere is a dovetail slot on the fire side of the plate for lining with silicon carbide bricks.<br \/>\nOne row of steel plates made of structural carbon steel 15\u041b with cast-in straight steel cooling tubes \u00d870x10mm is installed above the copper staves.<br \/>\nThere are two rows of cast-iron staves with cast-in straight cooling tubes above. Cast-iron grade \u0412\u0427 450-10, DSTU 3925-99, cooling tubes \u00d8 76\u00d79 mm are made of steel.<br \/>\nSix rows of cast-iron staves with cast-in coil pipes and cooling tubes are installed from el. +29,050 to el. 36,690. Cast-iron \u0412\u0427 450-10, DSTU 3925-99, cooling tubes are made of steel \u00d8 76\u00d79 mm.<br \/>\nThe subhearth water cooling system is designed as follows: 44 pipes \u00d8 60\u00d78 with a pitch of 250-350 mm between are laid under the bottom plate. The cooling pipes are combined in ten sections and poured-in with carbon concrete.<\/p>\n<p style=\"text-align: center;\"><strong>BF \u21164 PJSC \u00ab\u0410zovstal Iron &amp; Steel Works\u00bb<\/strong><\/p>\n<p style=\"text-align: left;\">In the scope of this project copper staves in the peak heat load zones (bosh and the first \u2013 fourth stack rows) and steel staves in the fifth and sixth stack rows have been installed, the pumping station has been revamped with installation of pumps, providing the cooling water speed of 2 \u2013 3 m\/s. The tuyer zone staves cooling has been changed to cooling with closed-loop demineralized water. The cooling rate in the stave coil tubes increased up to 2 \u2013 3 m\/s.<br \/>\nHeat exchangers of water\/air type have been installed for cold demineralized water cooling, that completely excludes sea water consumption.<br \/>\nThe following systems have been implemented: automatic cooling systems for the bosh, stack and the tuyer zone; control system for thermal load on the staves; control system for the lining condition in the stack and bosh; automatic stave burnout detection system.<br \/>\nTo compensate thermal loads between the staves, made of different materials (copper, steel, cast-iron), metal hoses with silicone coating are used.<br \/>\nAll cooling staves were fitted with dovetail joints for lining before installation.<br \/>\nTwo bosh and four stack rows (copper staves zone) as well as two rows of steel staves are lined with nitride bonded silicon carbide bricks (SiC content \u2265 70%, SI3N4 \u2265 21%), with lining thickness equal of 190 mm and more.<\/p>\n<p style=\"text-align: center;\"><strong>BF \u21164 PJSC \u00abIlich Iron &amp; Steel Works\u00bb<\/strong><\/p>\n<p style=\"text-align: left;\">&#8211; An automatic cooling system by means of cold demineralized water was developed within the framework of this project for the bosh, lintel and belly. The furnace stack was made in the form of &#8220;stack panels&#8221; where evaporative cooling system with natural circulation was kept. Process water supply is provided as emergency cooling for both systems.<br \/>\nAccording to the project of automatic bosh, lintel and belly demineralized water cooling system, the following works have been carried out:<br \/>\n\u2014 installation of copper staves in the bosh;<br \/>\n\u2014 construction of a new circulating pump station of demineralized water with installation of pumping units and frequency convertors for cooling rate control depending on heat load;<br \/>\n\u2014 installation of water\/water heat exchangers for heat dissipation from demineralized water by means of process water;<br \/>\n\u2014 installation of a control valve on the industrial water pipeline, which allows changing the volume of industrial water supply to heat exchangers depending on the ambient temperature and thermal load in the blast furnace. This solution allows to save up to 400 m\u00b3\/h of process water in winter and has been applied first ever in Ukraine in this project;<br \/>\n\u2014 installation of a modern automatic process control system.<br \/>\nDemineralized water manifold:<\/p>\n<\/div><\/section>\n\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-av_image-f28e65bcd669e7dd582d3de2c2dd482a\">\n.avia-image-container.av-av_image-f28e65bcd669e7dd582d3de2c2dd482a img.avia_image{\nbox-shadow:none;\n}\n.avia-image-container.av-av_image-f28e65bcd669e7dd582d3de2c2dd482a .av-image-caption-overlay-center{\ncolor:#ffffff;\n}\n<\/style>\n<div  class='avia-image-container av-av_image-f28e65bcd669e7dd582d3de2c2dd482a av-styling- avia-align-center  avia-builder-el-22  el_after_av_textblock  avia-builder-el-last '   itemprop=\"image\" itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/ImageObject\" ><div class=\"avia-image-container-inner\"><div class=\"avia-image-overlay-wrap\"><img fetchpriority=\"high\" class='wp-image-4451 avia-img-lazy-loading-not-4451 avia_image ' src='https:\/\/mtechnology.com.ua\/wp-content\/uploads\/2017\/12\/10.png' alt='' title='10'  height=\"396\" width=\"661\"  itemprop=\"thumbnailUrl\"  \/><\/div><\/div><\/div>\n","protected":false},"excerpt":{"rendered":"<p>Throughout the past 3 years \u00abM Technology\u00bb has participated in over than 30 blast furnace reconstruction projects.<\/p>\n","protected":false},"author":2,"featured_media":4453,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[32],"tags":[],"class_list":["post-5751","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-stati"],"_links":{"self":[{"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/posts\/5751","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/comments?post=5751"}],"version-history":[{"count":0,"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/posts\/5751\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/media\/4453"}],"wp:attachment":[{"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/media?parent=5751"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/categories?post=5751"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/tags?post=5751"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}