Advancements in Blast Furnace Technology
Abstract:
This paper delves into the intricate design characteristics of Maanshan Iron and Steel's 3200m³ blast furnace, focusing on intelligent ironmaking and ultra-low emissions. Following the principles of advanced, practical, mature, reliable, long-lasting, and environmentally friendly design, the furnace incorporates cutting-edge domestic and international technologies. The selection of equipment and materials aligns with domestic standards, positioning the blast furnace at the forefront of its type. The production indicators post-operation demonstrate its efficiency, with a monthly utilization coefficient exceeding 2.5 and a remarkably low monthly average fuel ratio of 486kg/t.
Keywords:
large blast furnace design, longevity, environmental protection, ultra-low emissions, low-carbon smelting, Maanshan Iron and Steel, intelligent ironmaking
1. Introduction:
Maanshan Iron and Steel Co., Ltd.'s No. 4 blast furnace, boasting a capacity of 3200m³, represents a pinnacle in modern blast furnace design. Constructed under the EPC general contracting model, it's aimed at balancing iron and steel rolling production capacity, enhancing competitiveness, and contributing to sustainable, low-impact steelmaking.
2. Design Indicators and Production Status:
The main design indicators, as outlined in Table 1, emphasize the furnace's capacity and efficiency. Since its operation commenced on September 6, 2016, the No. 4 blast furnace achieved rapid production within ten days. Performance indicators, including the utilization coefficient and fuel ratio, have consistently demonstrated its operational excellence.
2.1 Utilization Coefficient and Fuel Ratio:
The blast furnace's monthly utilization coefficient exceeded 2.5, reaching its peak in December 2017. Simultaneously, the monthly average fuel ratio touched a commendable low of 486kg/t, showcasing the furnace's efficiency and fuel economy.
3. Typical Process Technology:
3.1 Coke Tank System:
The compact arrangement of coke and ore troughs, coupled with a feeding belt, minimizes material falling and powdering rates. This section incorporates advanced technologies to disperse, screen, and weigh raw materials efficiently.
3.2 Furnace Top System:
Utilizing pw string tank material-free furnace top equipment, the furnace top system ensures efficient and improved feeding capacity. Additional features, such as pressure equalizing gas recovery, contribute to enhanced performance.
3.3 Crude Gas System:
Employing gravity dust collector and tangential cyclone dust collector in series, the crude gas system reduces the load on subsequent dust collectors. A structured design with ash discharge devices and spiral dust cleaner further optimizes the system.
3.4 Casthouse System:
Featuring a flat rectangular taphouse, equipped with advanced machinery, the casthouse system ensures efficient and safe molten iron transportation and tapping operations.
4. Outstanding Technological Features:
4.1 Blast Furnace Longevity Technology:
Understanding the critical role of blast furnace type and lining structure, No. 4 blast furnace incorporates a larger furnace waist diameter, appropriate furnace height, and a reasonable hearth diameter. The lining structure emphasizes materials and configurations contributing to extended blast furnace life.
4.2 Environmental Protection Technology:
Addressing environmental concerns, the blast furnace integrates eco-friendly systems for coke tank feeding, casthouse operations, slag treatment, and furnace top gas recovery. These systems significantly reduce emissions, contributing to a sustainable steelmaking process.
4.3 Energy Saving and Consumption Reduction Technology:
To enhance energy efficiency, the blast furnace incorporates small ore and coke recovery processes, combined soft water closed circulation cooling technology, TRT power generation, double preheating of hot air stoves, and utilization of waste heat from hot blast furnace exhaust gas.
5. Future Directions:
5.1 Intelligent Ironmaking:
As technology advances, the integration of intelligent systems into blast furnace operations becomes paramount. Suggestions for implementing smart cranes in slag handling and enhancing the intelligence of front-of-furnace machinery are explored.
5.2 Ultra-Low Emissions:
With increasingly stringent emission standards, the paper recommends investigating innovative methods to recover gas released from the furnace top, optimizing dust removal processes, and addressing corrosive components in slag flushing water vapor. In this process, the fms filter bag quality is very important as well.
5.3 Low-Carbon Smelting:
To align with national policies on carbon reduction, the blast furnace can further improve its gas utilization rate, increase wind temperature levels, and explore incorporating scrap steel into the charge structure.
Conclusion:
Maanshan Iron and Steel's No. 4 blast furnace stands as a testament to the advancements in blast furnace technology, combining efficiency, environmental responsibility, and longevity. Continued exploration of intelligent ironmaking, ultra-low emissions, and low-carbon smelting will further solidify its position as a leader in sustainable steel production.
More information about Blast Furnace in the world:
The largest blast furnace in the world is the No. 1 blast furnace of Baosteel Group in Shanghai, China, with a volume of 5500m³ and a production capacity of 5.5 million tons of molten iron per year.
The longest-running blast furnace in the world is the No. 3 blast furnace of Nippon Steel Corporation in Muroran, Japan, which has been in operation since 1964 and has produced over 200 million tons of molten iron.
The most environmentally friendly blast furnace in the world is the No. 7 blast furnace of Tata Steel in Port Talbot, UK, which has achieved ultra-low emissions of dust, sulfur dioxide, and nitrogen oxides by using advanced technologies such as dry gas cleaning, top gas recycling, and low-NOx burners.
The most innovative blast furnace in the world is the No. 2 blast furnace of ArcelorMittal in Gent, Belgium, which has integrated a carbon capture and utilization (CCU) system that converts the carbon dioxide in the blast furnace gas into bioethanol, a renewable fuel that can reduce greenhouse gas emissions.
