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Abstract : The performance of a blast furnace is considerably influenced by burden distribution. The bed permeability and efficiency of gas utilization are improved by proper distribution of burden materials. The burden distribution is significantly affected by adopting different types of charging system. The charging sequence plays specific role in each type of charging system. The Paul Wurth bell less top charging system offers more flexibility in distribution of burden materials at any desired location. The furnace performance with regard to productivity, fuel rate and hot metal quality can be certainly improved by changing the burden distribution pattern Key words : Burden distribution, Performance. Blast furnace process, Charging device. Productivity, Fuel rate, Hot metal qualigt Burden trajectont Temperature profile.
INTRODUCTION
The Blast Furnace is a countercurrent packed bed reactor being successfully used in all integrated iron and steel plants of the world to produce hot metal. The cost and quality of hot metal produced is directly related to its stable operation. The blast furnace burden generally comprises of sintered material, lump ore, pellets, coke, lumpy BOF slag and fluxes. During charging the burden materials tend to segregate radially according to their size, density and operating characteristics of the distribution system. The burden distribution during charging system has proved to be vitally important for the operation of the blast furnace. It determines to a great extent gas permeability and its distribution and hence reduction and smelting of the charged materials. It thereby influences output, fuel consumption and furnace campaign. The-^pe of charging equipment used and its mode of application plays a key role in the burden distribution and the operation of blast furnace. Both burden distribution and gas flow distribution play major role in deciding the stability of furnace. Since 1960, the burden distribution control technology has made rapid progress through (i) the introduction of the movable armor and the bell-less charging equipment (ii) the usage of newly developed probes''' for measuring the gas flow distribution and the burden profile and (iii) improvement of control accuracy made through studies with physical model experiments,' , and estimation with mathematical models'41. From seventies it is urged to improve the yield of raw materials and fuels for energy conservation. In a large size reactor like blast furnace, it is extremely difficult to acquire uniform burden distribution and uniform gas flow to acquire optimum operating conditions for stable performance. Burden distribution has acquired more significance in recent times when it is essential to drive the furnace at higher rates for higher productivity, with higher injection rates of pulverized coal to decrease coke consumption. The developments in burden distribution and its significance in furnace performance have been outlined.
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SIGNIFICANCE OF BURDEN DISTRIBUTION In the dripping zone, the gas flows primarily through annulus formed by the "deadman" and inner boundary of cohesive zone and finally it goes out through the coke slits. The factors that influence the furnace performance significantly are burden distribution at the stock level and high temperature properties of burden. Thus, one can conclude that the cohesive zone influences the gas distribution in the furnace and,its size and shape are determined by the burden distribution and high temperature properties of burden materials. The sizes of lumpy zone and dripping zone are also determined by these factors. It can therefore be clearly implied that for stable furnace operation, the cohesive zone must be stable. FLOW PATTERN OF GAS IN STACK ZONE
In a blast furnace reducing gas ascends and reduces the descending iron oxide particles. Raw ln'aterials are charged in alternate layers of ore and coke into the stack zone . They retain their layered arrangement as they move downward countercurrent to the flow of gases that preheat and prereduce these iron -bearing granular materials . The reducing gas is generated initially in the raceway zone by the combustion of coke and injectants with oxygen from the hot blast. The gases flow upward in the active coke zone and into the stack zone through the coke slits in the cohesive zone where the ore starts to melt . In the stack, the coke is larger and more permeable than-the ore , gas flows preferentially towards those regions where the coke layers are relatively thicker than the ore layers . Within the ore layers , the gas flows preferentially away from smaller particles . The principal zones of the blast furnace as determined from dissected furnace"--"' are shown in Fig. 2.
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Fig. 3 : Temperature profiles of six characteristic distributions. analysis. The temperature profiles of six characteristic distributions are illustrated in Fig. 3. These six temperature profiles are
- Flat profile
- Inverse `V' or `U' shape profile - `W' shape profile with some peripheral gas flow - `W' shape profile with considerable peripheral gas flow - Inverse `V' shape with some peripheral gas flow - Inverse `V' shape with little peripheral gas flow Flat Profile The flat profile of temperature distribution is obtained in abnormal situation such as with marked decrease in wind acceptance or major hangings etc. Inverse `V' or 'U' Shape Profile This type of profile corresponds to a quite rare state possibly with an inactive deadman. This type of profile may be obtained during operation with high-pulverized coal injection (PCI) rates, which do not undergo complete combustion in the raceway. `W' Shape Profile with Some Peripheral Gas Flow It is a well-balanced profile. It corresponds to a situation where slight gas flow occurs along the wall and prevents the formation of accretions.
`W' Shape Profile with Considerable Peripheral Gas Flow This type of profile corresponds to a furnace state in which an excessive peripheral gas flow occurs to clean up the build-ups on the wall. Inverse `V ' Shape Profile with Some Peripheral Gas Flow This type of profiles corresponds to a situation where slight gas flow occurs along the wall and more pronounced gas flows in the central region. This type of profile corresponds to operations with low fuel rate. Inverse `V ' Shape Profile with Little Peripheral Gas Flow This type, of profile corresponds to a situation with little peripheral gas flow. It is a good profile with superior physico-chemical characteristics of raw materials.
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ratio and particle size segregation can be closely controlled in the wall and intermediate regions and can be strongly influenced in the central part of the furnace . With movable armor, layer charging is used to permit a different setting for each burden material.
EFFECT OF CHARGING PRACTICE ON BURDEN DISTRIBUTION AND GAS FLOW IN FURNACES WITH DIFFERENT TYPES OF CHARGING SYSTEM Furnaces with Bell-Top Charging System
In bell type charging system, the burden distribution characteristics are basically as illustratedl"I in Fig. 8. The burden material is charged near the wall of the furnace and it'rolls towards the furnace center according to its angle of repose. As it rolls down towards the center, the burden material classifies itself into size fractions. The fine fraction remains at the impact point near the wall and the coarse fraction is deposited at the terminal point of rolling in the furnace center. The segregation of the burden material is influenced by their discharge characteristics from the charging apparatus. The angle of repose varies with the velocity of the ascending gas as shown"") in Fig. 9 and the angle of inclination of the ore and coke layers is influenced accordingly. The ore and coke are distributed as schematically illustrated""' in Fig. 10 and assume characteristic layer profiles depending on whether the coke layer collapses when ore is charged after coke or coke is positioned away from the furnace wall. These characteristics arise from the distribution of profile of coke, which are designated V, M and U shaped respectively.
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The most commonly used filling sequences are forward till and the layer fill. The forward fill corresponds to OOCCC/. where 0 = ore skip, C= coke skip and /= larger bell dump and the layer fill corresponds to OO/CCC/. Likewise the reverse tilling corresponds to CCCOO/ and produces strong wall flows and can help removal wall accretions but at the expense of furnace efficiency. Different charging practices have different effect on burden distribution and gas flows as mentioned below:
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- Increased percentage of pellets in the charge takes more ore towards furnace center. As a result the gas flow is decreased in the central region and increased towards wall region. Reverse fill Maces a layer of coke on wall and more coke and fines in the furnace center. Reverse fill causes increased flow of gas right on the wal: and in the furnace center. It leads to less reducing gas utilization. Layer fill places more ore in the furnace center. It leads to decreased flow of gas in the central region and increased flow in the wall region. - Increased batch size places more coke in the furnace center, which leads to increased flow of gas in the central region and decreased flow of gas in the wall region. - Decreased coke/ore ratio also places more ore in the furnace center, which leads to decreased flow of gas in the central region and increased flow of gas in the wall region. In order to obtain high performance and on all- coke operation, the material distribution had to be adjusted to provide a more centralized gas flow with correspondingly decreased gas utilization and higher fuel consumption. Therefore in order to reduce the fuel rate, the gas utilization can be improved by appropriate adjustment of skip sequences, stock line level and coke base. In bell type top charging system, which has no movable throat armour, the material distribution, gas permeability and its distribution are controlled by means of stock line level, charging sequence and coke base. Generally a temperature probe is installed above the stockline level relatively soon after commissioning to permit conclusions as to what material distribution would be best suitable for gas permeation and furnace operation under the existing burden conditions. Apart from conventional process control with respect to pressure loss, top gas temperature and gas utilization, the probes are inserted to measure the gas temperature distribution over the furnace radius above stockline level. The stockline level has considerable effect on gas distribution, permeability and gas utilization. For constant charging sequence of CCS.IS.ICC.IS.IS.I the influence of stockline level on gas distribution is illustrated1 1 in Fig. 11. One can clearly note that with the lowering of the stockline level, the gas temperatures are reduced at furnace wall and increased at the furnace center. It can be seen that the most favourable stock line level in respect of pressure loss and gas utilization is proved to be about 2.7 m below the closed bell. Further Fig. 12 indicates"1 the influence of various charging sequences on the gas distribution for the stock line level 2.7m. The most appropriate charging sequence CCS/S/CC/S/S is compared with the basic charging cycle of
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center
Furnaces with Paul Wurth Bell - Less Top Charging System In furnaces with Paul Wurth Bell-Less Top charging system, the effects of material charging and distribution depends on chute operation. It offers more flexibility of distributing the materials at any desired location. Great control over the material segregation can be practiced using PW bell-les top charging system. The instrumentation and control panel controls the chute RPM, chute angle, chute swing speed and chute revolutions in a particular ring in Paul Wurth Bell-Less Top system of charging. Weighed quantity of sized raw materials namely ore, sinter and coke in the specified proportions are individually charged. The raw materials are thus filled in layers. The stock level is maintained by synchronizing the charging and discharging rates. During the filling of raw materials one can study the formation of layers of different materials and their shape/ profile, segregation or distribution of finer size fractions, trajectory of the falling burden stream and landing of particles, formation of peak in the individual layer, shifting of the peak position and rolling down of particles from the peak etc. This basic phenomenon can be captured/ photographed by means of video camera. The process of charging is continued till layer profiles are stabilized generally the top layer and 5 to 6 layer below the top layer are of academic interest. This charging study gives an idea of bed permeability, gas distribution through the burden layers and radial temperature distribution profile of the gases ascending through the burden column. In actual operation, the active and inactive regions, of the furnace can be identified and corrective action can be taken under stable operation, all regions namely central, intermediate and peripheral remain fully active over the entire cross section. The stock line profiles of the various charged materials can be measured by means of non-conducting ultrasonic sensing system and the radial distribution of burden /coke ratio can be determined. A specially designed collecting device can also determine the particle segregation of sinter and coke. Fig. 16 showst'`'t the results of such profiles measurements and of the particle distribution. Two charging patterns have been
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A.K.VAISH and R. K.MINJ DEMAG / PAUL WURTH BELL-LESS TOP CHARGING SYSTEM ITS SPECIAL FEATURES The gas distribution within the furnace and thus furnace efficiency is substantially influenced by the precision with which the burden is distributed with the Demag / Paul Wurth bell-less top. This system is characterized by a significantly more uniform distribution of burden components than that achieved with a bell-top with an adjustable throat armour system. The Demag / Paul Wurth bell-less top enables the charge to be distributed selectively over the entire furnace throat cross section by means of a rotating distribution chute. Changing chute angle or the ring number of the chute can dump the charge material at the desired place to provide uniform permeability of the stock cross-section. It has greater flexibility of the charging pattern than that of any other system. In general, more gas passes through regions containing more coke resulting in a higher temperature of the region. Therefore, more coke is desired in the central region to make the furnace central working which results in lower thermal load on the wall and leads to efficient and smooth working of the furnace. In view of this fact generally coke is charged into rings more towards the centre and metallics are charged towards the periphery. It overall results in lower coke rate and higher efficiency of gas utilization.
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SIGNIFICANCE OF BURDEN DISTRIBUTION CONCLUSIONS - The development of bell-less top charging system is a noteworthy achievement in the direction of uniform burden distribution in the furnace. - The gas distribution within the furnace and its efficiency are substantially influenced by the precision with which the burden is distributed. - The desired improvement in heat transfer and gas distribution can be achieved by changing the burden distribution pattern without adversely affecting the gas permeability. - The in-depth burden distribution studies can improve the blast furnace performance with regard to productivity, fuel rate and hot metal quality.
REFERENCS
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