{"id":5890,"date":"2016-02-26T16:28:48","date_gmt":"2016-02-26T14:28:48","guid":{"rendered":"http:\/\/www.mtechnology.com.ua\/?p=5890"},"modified":"2023-02-16T20:27:40","modified_gmt":"2023-02-16T18:27:40","slug":"modern-cooling-system-philosophy-implemented-by-m-technology-llc-at-blast-furnace-no-2-of-pjsc-zaporizhstal","status":"publish","type":"post","link":"https:\/\/mtechnology.com.ua\/en\/modern-cooling-system-philosophy-implemented-by-m-technology-llc-at-blast-furnace-no-2-of-pjsc-zaporizhstal\/","title":{"rendered":"Modern cooling system philosophy, implemented by \u00abM TECHNOLOGY\u00bb LLC at blast furnace No. 2 of PJSC \u00abZaporizhstal\u00bb"},"content":{"rendered":"

In 2013 a number of problems with the lining and furnace cooling system of blast furnace No. 2 at PJSC \u00abZAPORIZHSTAL\u00bb have occured as a result of intensive operation and pulverized coal injection:<\/p>\n

The bodies of cast-iron staves of the 4-th row of the evaporative cooling system were completely destroyed, in the 5-th row the staves were partially destroyed and in the 6-th row the stave bodies had cracks. Thus, bare steel pipes without lining and cast-iron stave body remained in the cooling system of the 4-th and 5-th rows.<\/p>\n

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In places where the staves were destructed, the cooling system did not fulfill its function.Overheatings of the blast furnace shell took place. There were red stains on the armor and, as a result, a strong shell deplanation occured.<\/p>\n

Together with \u00abZAPORIZHSTAL\u00bb experts, the following BF cooling system repair has been undertaken:
\n– installation of copper cooling staves in the most heat-loaded zones of the blast furnace in combination with a highly conductive lining;
\n– application of modern pumping equipment of our own production with frequency regulation;
\n– implementation of modern automation systems for cooling intensity control depending on the thermal loads in real time.<\/p>\n<\/div><\/section>\n

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\u041f\u0440\u0438\u043d\u0446\u0438\u043f\u0438\u0430\u043b\u044c\u043d\u0430\u044f \u0441\u0445\u0435\u043c\u0430 \u0441\u0438\u0441\u0442\u0435\u043c\u044b \u043e\u0445\u043b\u0430\u0436\u0434\u0435\u043d\u0438\u044f<\/div><\/div><\/div><\/figcaption><\/figure><\/a>
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\u0423\u0441\u0442\u0430\u043d\u043e\u0432\u043a\u0430 \u043c\u0435\u0434\u043d\u044b\u0445 \u0445\u043e\u043b\u043e\u0434\u0438\u043b\u044c\u043d\u044b\u0445 \u043f\u043b\u0438\u0442 \u043f\u043e\u0441\u0442\u0430\u0432\u043a\u0438 PAUL WURTH<\/div><\/div><\/div><\/figcaption><\/figure><\/a><\/div><\/div>\n

As a result of the work performed, the following functions of the automated control system for chemically treated water cooling have been implemented:
\n\u2014 automatic pump performance control depending on the copper staves thermal load and based on temperature measurements along the staves belt;
\n\u2014 automatic turn-on of pumping station power supply feeders in case of any working pump failure;
\n\u2014 operation of pumps in automatic, remote or local mode;
\n\u2014 water level regulation in separator tanks No. 1,2 in automatic, remote, local modes by means of ball valves;
\n\u2014 data display on the BF No.2 foreman’s work station, as well as on CP-1, CP-2 control panels, installed in the BF foreman room and pumping station;
\n\u2014 vibration monitoring to control the vibration level of pump bearing assemblies and their drive motors;
\n\u2014 advanced system of automated process control system diagnostics, including fault detection of PLC modules, frequency converters, network components, etc.<\/p>\n<\/div><\/section>\n

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Pumping station of BF \u21162 cooling system.<\/h3><\/div><\/div><\/figcaption><\/figure><\/a>
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Control room of BF \u21162<\/h3><\/div><\/div><\/figcaption><\/figure><\/a><\/div><\/div>\n

Implementation of this project made it possible to achieve the following results:<\/p>\n

1. Energy saving through the use of frequency control.<\/p>\n

As shown by operating experience, basically, the pumps operate at the first speed and switch to the second and third speed only after skull slipping. At the same time, the scull on the lining builds up in just a few hours, after which the pumps return to the first speed again. Energy saving is up to 240 kW per hour.<\/p>\n

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2. Maintaining a stable skull layer on the lining prevents it from wear and allows you to minimize the heat loss of\u00a0the furnace with a cooling system and, as a result, to save coke consumption.<\/p>\n

After six months of the blast furnace operation the average temperature of copper staves is 114 \u00b0 C and remains unchanged from the moment of the furnace blowing-in.<\/p>\n

3. The steam capacity of the cooling system has decreased almost 4 times and is about 2 \u00f7 2.5 t \/ h from one section, heat losses with the cooling system have been decreased, the flow rate of supplied chemically treated deaerated make-up water has been reduced.<\/p>\n

4. Frequency regulation in combination with an automation system also eliminates the accretion due to intense cooling.<\/p>\n

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Display of cooling staves’ temperatures of\u00a0 after 6 months of operation.<\/p>\n

All above mentioned solutions extend the blast furnace campaign under the condition of PC injection to 15-20 years between overhauls, and the use of modern automation systems helps to quickly manage cooling processes and to simplify maintenance.<\/p>\n<\/div><\/section>\n","protected":false},"excerpt":{"rendered":"

In 2013 a number of problems with the lining and furnace cooling system of blast furnace No. 2 at PJSC \u00abZAPORIZHSTAL\u00bb have occured as a result of intensive operation and pulverized coal injection: The bodies of cast-iron staves of the 4-th row of the evaporative cooling system were completely destroyed, in the 5-th row the […]<\/p>\n","protected":false},"author":2,"featured_media":4221,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[32],"tags":[],"class_list":["post-5890","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\/5890","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=5890"}],"version-history":[{"count":0,"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/posts\/5890\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/media\/4221"}],"wp:attachment":[{"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/media?parent=5890"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/categories?post=5890"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/mtechnology.com.ua\/en\/wp-json\/wp\/v2\/tags?post=5890"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}