INTRODUCTION

Qatar Steel Company ( QASCO ) is the first integrated steel plant in the middle east. It was incorporated in the year 1978,in collaboration with KOBE STEEL of Japan. Qascos main products are billets and Steel bars. The main plants in QASCO are; 1- Direct Reduction Plant ( D.R ) 2- Electric Arc Furnaces ( E.F ) 3- Continuous Casting Mills ( C.C ) 4- Rolling Mills ( R.M ) QASCO receives iron ore in the form of pellet or lump ore from countries like Bahrain, Brazil and Sweden. It is unloaded from ships to the Material Control yards from where it is supplied to D.R through a series of conveyor system. In D.R, iron oxide is reduced to sponge iron in the vertically mounted shaft furnace using reducing gases such as hydrogen and carbon monoxide. This sponge iron is conveyed to electric arc furnace through different conveyor system. Sponge iron is melted and refined in the Electric Arc Furnaces and then casted into billets form in the Continuous Casting Shops. Billet is also a saleable product which QASCO exports to other countries. The billets are re-heated and rolled through different strands in the Rolling Mills and finally produces the saleable steel bars. QASCOs products are sold in local markets as well as exported to other countries.

D.R. PLANT
D.R. Plant was commissioned in the year 1978 and started commercial production from the month of August 1978. This is a 400 series module, gas based direct reduction plant , based on Midrex technology. The original capacity of the plant was 52 T/Hr. Owing to different debottlenecking process and other modifications, D.R Plant production rate has now increased above 96 T/Hr. The main facilities in the D.R plants are; 1- Reduction Furnace 2- Reformer and Heat Recovery System 3- De-sulphurizing Facility. 4- Oxygen Injection System and Oxide Coating System 5- Main Control Room. The reduction furnace is used for reducing the oxide pellet to sponge iron and reformer for making the reducing gases. Iron oxide is continuously charged into the vertically mounted furnace from the top. In the furnace, the iron oxide undergoes through a series of reduction reactions with hot reducing gases such as hydrogen and carbon monoxide. The reduced pellets are cooled in the lower part of the furnace by a circulating cooling gas system before discharging through the bottom of the furnace. Reducing gases are made in the reformer using natural gas as a feed stock. De-sulfurizing facility is to remove hydrogen sulfide from the natural gas before being introduced into the reformer. Hydrogen sulfide is a poison to the reformer catalyst and will reduce its activity. Oxygen injection system and oxide coating system are plant improvements carried out in the year 2003, to enhance productivity. The plant facilities can be categorically sub-divided in to different systems ( respective code numbers also given ). A B C D E F G H M S Process system Combustion system Flue gas system Seal gas & Purge gas system Process water system Oxide material handling system Instrument & Plant air system Product material handling system Machinery cooling water system Sea water system

D.R.Process
The method of producing sponge iron from iron ore through reduction reactions is known as direct reduction process. There are different types of direct reduction process in the world, such as a) Midrex Process b) Puofer Process c) Hyl Process and d) SL/RN process. QASCO adopted the Midrex Process. Midrex process has two main facilities, one is a reduction furnace and the other is a reformer. The reduction furnace is used for reducing the oxide pellets to sponge iron, and the reformer is used for making reducing gas. The main raw material for direct reduction plant is iron oxide in the form of pellet. Lump ore is also used in some plants because of its low cost in comparison to pellets. Natural Gas is the other raw material used in D.R plant for making reducing gases in the reformer. Natural gas is converted in to carbon monoxide ( CO ) and hydrogen ( H2 ) which is used as the reducing gases. Iron oxide pellets or lump ore are charged into the vertically mounted reduction furnace from the top. It is treated in the reduction zone of the furnace with reducing gases consisting of H2 and CO at a temperature range of 900 ~ 985C.The iron oxide, having the main constituent Hematite ( Fe2O3 ) is reduced to sponge iron after the following chemical reactions; Fe2O3 + 3H2 = 2Fe + 3H2O Fe2O3 + 3CO = 2Fe + 3CO2. The reduced pellet is further subjected to carbon forming reactions, with carbon monoxide and methane. 3Fe + 2CO = Fe3C + CO2 3Fe + CH4 = Fe3C + 2H2 In the lower part of the furnace, the hot sponge iron is cooled by the cooling gas before discharging through the bottom of the furnace. The spent gas from the furnace is again circulated by the process gas compressors through the reformer where it is reformed in to CO and H2 by reacting with hydro- carbons, mainly CH4. The reactions are; CH4 + H2O = CO + 3H2 CH4 + CO2 = 2CO + 2H2 The required temperature for these endothermic, reforming reactions is supplied by 110 main burners and 33 auxiliary burners spread across the reformer. Natural gas is the fuel in the auxiliary burners where as, in the main burners, natural gas plus a portion of return gas from furnace are the fuels .The burnt gas in the reformer is known as flue gas which contains mainly nitrogen, water vapor, carbon dioxide and small amount of oxygen. The heat energy is recuperated from the flue gas partially to heat up the burner air and reformer feed mix gas and finally the flue gas is vented to atmosphere through stacks.

PROCESS GAS SYSTEM

This system is used to produce the reducing gases in the reformer and to circulate the reducing gases for reduction. Process gas system consists of a top gas scrubber, 2 first stage blowers, one second stage blower, silencers at the discharge of each blowers, one feed mix gas mixer, one mist eliminator, two pre-heaters, 220 reformer tubes and a reformed gas cooler. Hot spent gas from the furnace of 350C ~ 400C, leaves the top of the furnace and is sent to top gas scrubber where it is cooled and cleaned by direct contact with circulating water. The scrubber is divided in to two compartments, known as top gas fuel section and process gas section. The scrubber is filled with polypropylene saddles.1/3 of the gas , being surplus gas , is sent to reformer as a fuel in the main burners. 2/3 of the gas is again circulated by the process gas blowers through the preheaters and then to reformer and back to the furnace. Natural Gas is injected in to the process gas through the mixer, which is located before the pre-heaters. This gas is known as feed mix gas. Pre-Heater preheats the mixed gas to a temperature of about 425C. This heated gas is distributed in to four headers situated below the reformer from where , again the gas is distributed to 220 reformer tubes. The tubes are filled with nickel based alumina catalyst to speed up the reforming reaction within the tubes. Tubes outlet gas is known as reformed gas which contains mainly hydrogen and carbon monoxide with small quantity of water vapor, carbon dioxide, hydro carbons and nitrogen. Temperature of the reformed gas is controlled to about of 910C by controlling the reformer burner temperature. The temperature and methane content of the reformed gas is then controlled to a suitable value before it is sent to furnace as the reducing gases. This gas is known as bustle gas. Bustle gas temperature is controlled in two ways. During plant start- up and shut down, bustle gas temperature is controlled below reformed gas temperature or at minimum. This is done by passing a part of the reformed gas through the reformed gas cooler. Reformed gas cooler is filled with stainless steel saddles. Cold contaminated water is sprayed above the packing which passes through the packing and cools the counter current gas. During normal plant operation, the plant is operated with higher bustle gas temperature than the reformed gas temperature. This is done by injecting oxygen in to the reformed gas header. Localized combustion takes place in the reformed gas duct and increases the temperature. This system is known as oxygen injection system and it is situated at the reformed gas cooler platform. Methane content of the bustle gas is also controlled by adding natural gas into the system. This gas then enters the furnace through 72 bustle ports situated all around the furnace bustle area. This gas, flows through the furnace upward, reacts with the descending oxide pellet , and finally escapes through the furnace top off take duct.

COOLING GAS SYSTEM

The purpose of this system is to cool the hot product after the reduction reactions and bring the temperature close to atmospheric temperature, before the material is discharged from the furnace. The main equipments in the cooling gas system are; 1- Cooling zone scrubber 2- Cooling zone blower. 3- Cooling zone mist eliminator. The metallized product descends from the reduction zone to the cooling zone. The product is too hot to discharge from the furnace. To prevent re-oxidation of sponge iron, hot metallized product must be cooled to near ambient temperature. The cooling gas enters the lower portion of the cooling zone through a cooling gas distribution cone and passes through the product. Cooling gas is evenly distributed in the reduction furnace through a facility called Christmas tree. Cold gas is moved upward in the furnace, cools the descending material then finally comes out of the furnace through the gas off takes. Gas off take temperature is controlled by regulating the cooling zone gas flow. Hot cooling zone gas comes out from the furnace through three cooling zone off-takes. This gas is scrubbed and cooled in the cooling zone scrubber. The clean and cold gas is then compressed and again pushed back in to the furnace after removing the mist through a mist eliminator. Natural gas is injected in to the cooling zone gas to maintain a methane enriched gas composition which helps to control the product carbon content as required in the melting shop. The basic carburizing reactions are as follows; 3Fe + 2CO = Fe3C + CO2 3Fe + CH4 = Fe3C + 2H2 Cooling zone gas flow and cooling zone natural gas flow are monitored and controlled from control room as desired by the prevailing operating condition and carbon requirement in the product.

COMBUSTION SYSTEM
Combustion system function is to maintain the reformer to be at the reforming temperature. This system can be classified in to two, 1) Auxiliary combustion system. 2) Main combustion system.

Auxiliary Combustion System

This system consists of an auxiliary air blower and 33 pre-mix type auxiliary burners which are lit at all times except the plant status is cold. The purpose of this system is for initial dry out of refractory and bring the reformer up to 1010C idling temperature , to maintain a minimum temperature during extended idling and idling and to compensate heat losses during operating condition. This system helps the main burner to lit themselves. Natural gas is the fuel used in the auxiliary combustion system. 33 burners are spread across the reformer in three rows. Each row is equipped with a pressure regulator and a zero regulator so as to control the ratio of natural gas that to the air.

Main Combustion System

The main combustion system is used to maintain the reforming temperature while the plant is in operating condition. This system consists of a centrifugal blower which provides air to the diffusion type main burners. There are total 110 main burners. Out of this ,44 burners are of 3 mm capacity and 66 burners are of 6 mm capacity. The main fuel gas for this burners is the top gas fuel which comes as excess quantity after the reduction reaction. This comes roughly 30% of the total process gas. 70% of the heat input to main burners is supplied by the top gas fuel. The balance is made up from the natural gas. Top gas fuel and natural gas are mixed in fuel gas mixer before being supplied to each burners. This mixed fuel gas freely burns in the main burners. The required air is supplied by the main air blower. This air is pre-heated to a temperature of about 550C by hot flue gas in the recuperators. Reforming reaction takes about 60% of the heat generated by the main burners. The remaining is used as sensible heat. All these burners are situated at the bottom part of the reformer. These burners are properly spaced and spread across the reformer bottom to supply a uniform heat out put. In order to monitor the reformer temperature , there are 31 thermocouples fixed across the reformer and its readings are displayed in control room.

SEAL GAS SYSTEM

The main purpose of seal gas system is to maintain a dynamic sealing at the furnace top and bottom. It also provide inert gas to product load out system to maintain a positive inert atmosphere to safeguard against reoxidation of sponge iron. The main equipments in the seal gas system are; seal gas cooler, seal gas compressors, seal gas after cooler and a mist-eliminator. Spent gas from the reformer which is known as flue gas is cooled, cleaned and demisted to be used as seal gas. Hot flue gas is cooled in the seal gas cooler using contaminated water as the coolant. This gas is then compressed to 1.35 ~ 1.40 kg/cm2 pressure by a two stage compressor known as seal gas compressor. From the compressor, seal gas is passed through a shell and tube heat exchanger known as after cooler. MCW is the coolant in the seal gas after cooler. Carry over mist is then removed through a mist eliminator. This partially wet seal gas is used at the furnace top and bottom to maintain a sealing against the furnace gases. A portion of the seal gas is dried via seal gas drying system and used in the product silo, dust and fines bins, bucket elevator and product screen in order to maintain an inert atmosphere. The drying system consists of a seal gas scrubber, two pre-filters, two refrigerant dryers, two desiccant dryers and two after filters. Purpose of the scrubber is to scrub any carry over carbon particle present in the seal gas. Refrigerant dryers cools the gas to a lower temperature of 2~ 4 C and allows the water particle to condensate and get removed. Final removal of carry over mist is done in the desiccant dryer which is filled with silica gel. Silica gel adsorbs the mist particle. There are two desiccant dryer in which one will be on line at a time for a period of 9.9 hrs and the other undergoes a regeneration process for a continuous cyclic operation. After filter prevents any silica gel powder carry over into the system. A part of dry seal gas is compressed by the purge gas compressor and stored in two purge gas tanks. This stored purge gas is used for system purging / system diluting whenever a need arises. When the reformer combustion system is not operative and to meet excess demands, an emergency inert gas generator is provided to supply seal gas.

HEAT RECOVERY SYSTEM

System which handles the hot flue gas from the reformer is known as flue gas system or heat recovery system. Hot flue gas from the reformer is utilized to heat up the process gas in the pre-heaters and combustion air in the recuperator. The main equipments in this system are; 1- Dilution Air Blower. 2- Recuperator ( 2 numbers ) 3- Power Stack & Power Stack Fan 4- Pre-Heaters ( 2 numbers ) 5- Pre-Heater Fan Dilution air blower provides cold air by which the temperature of the hot flue gas is controlled. Temperature of flue gas need to be controlled below 1050 C to safeguard the recuperator tube bundles. Recuperator is nothing but a shell and tube heat-exchanger. In each recuperator, there are two tube bundles , one is shock pass bundle and the other main pass bundle. Combustion air is passed through this tube bundles to elevate its temperature to 550 C. The out let flue gas from the recuperator will carry a temperature of about 700 C. Purpose of power stack fan is to provide forced staking of flue gas through the recuperators and maintain a negative atmosphere in the reformer. In the second stream, pre-heater fan suck flue gas through two preheaters and vent out the gas to atmosphere through its stack. Pre-heater is a shell and tube heat exchanger, where process gas is pre-heated to a temperature of about 425C. Here, process gas passes through the tubes and flue gas through the shell.

COOLING WATER SYSTEM

Cooling water system is designed to minimize water consumption by utilizing sea water as a coolant. The cooling water system is divided in to two sub-system; contaminated water system and clean water system.

Contaminated Water System

Water in this system is provided to the process gas system for gas cooling and cleaning. The main equipments in this system are; circulating water pumps, heat exchangers, water supply and return lines, mixing tank, classifier, thickener tank and sump. From the sump, water is pumped by the multi stage turbine pumps, which through the heat exchangers and sent to top gas scrubber, cooling zone scrubber, seal gas cooler, reformed gas cooler and seal gas scrubber. The dirty and hot water return from these vessels are taken to a mixing tank and then to a clarifier. In clarifier, water is refurbished by sedimentation method. From the clarifier water over flows to the contaminated water sump and the sediments settles in the bottom of the clarifier from where it is pumped to the thickener tank , and then to outside settling pond. Additional water is supplied from fresh water to compensate sludge draw off and evaporation. This water also provided to the dust collection system. Cold water is used in process dust collection ventury and hot water in product and load out venturies.

Clean Water System or Machinery Cooling Water System

Several machines require cooling to remove the heat generated by friction and/or compression. So this system used for this purpose and known as machinery cooling water system. It consists a sump, circulating water pumps, heat exchangers and distribution and return lines. Multi stage turbine pumps circulate the water through the heat exchanger and supplies to different oil coolers, bearings and indirect gas coolers and back to the clean water sump. Loss of water by evaporation is made up by fresh water.

Upper Cluster Breaker Water System

The purpose of this system is to provide clean water for cooling upper cluster breakers. This system consists of a sump, circulating water pumps, heat exchanger , the supply/ return lines and one water trough.

MATERIAL HANDLING SYSTEM

Material handling system is equipped to convey the oxide pellet/ lump ore from the oxide storage yard to the reduction furnace, to discharge the metalized product from furnace , to store it and to provide it to the melt shop. There are three sub-system in this material handling system. They are, oxide feed system, product discharge system and product load out system.

Oxide Feed System

The oxide pellet is reclaimed from the oxide yard with a stackerreclaimer, convey to the day bins. From day bins, pellet is fed to the furnace charge hopper according to the demand. Discharge feed rate is set in the day bin discharge weighing scale feeder as per the days oxide blending ratio and production rate. From day bin discharge feeder, material is conveyed to two oxide screens by day bin discharge conveyor. Screened material ( above 3.2 mm size ) is then conveyed to furnace charge hopper by conveyors namely screen discharge conveyor, oxide transfer conveyor and furnace feed conveyor. From the oxide screen, under size pellet is removed , conveyed to the fine slab by oxide fines conveyor.

Product Discharge System

Sponge iron is discharged from the furnace by wiper bar system. From wiper bar, material is discharged to furnace discharge conveyor from where it is conveyed to either product storage silo or remet slab according to the grade of the material. Only A-grade quality sponge iron is stored in the product silo. Lower grade material is diverted to remet slab and will be stored in the yard. A grizzly is provided before silo to remove aggregated clusters or any other foreign material from the furnace discharge material. Sponge iron is stored in the product silo , which is always kept under sealing with dry seal gas.

Product Load Out System

Product is discharged from silo by a vibrating feeder and conveyed to a product screen. Under size pellet , below 6.4 mm size is removed by screening in the product screen. Then screened material is supplied to electric arc furnace hopper according to their demand. Under sized product from the screen is conveyed to a fines bin for separate use in electric arc furnace. Excess material in silo is transferred to different yard by loading the material in trucks.

DUST COLLECTION SYSTEM

There are three dust collection system in D.R namely process dust collection system, Product dust collection system and load out dust collection system. Each dust collection system is equipped with a cyclone, ventury , mist eliminator , fan and related piping. The collected dust is stored in a dust bin under seal gas sealing and is emptied via trucks regularly. Process dust collection system is used for furnace discharge area. It collects dust from wiper bar box, furnace discharge conveyor , grizzly feed conveyor tail side and remet conveyor tail and head side. Product dust collection is used for product handling area and storage area. The area it covers is; grizzly feed conveyor head side, grizzly, silo feed conveyor head and tail side and silo discharge. Load out dust collection system is for load area, i.e. silo discharge conveyor head chute, product screen, reversible conveyor, product fines conveyor and bucket elevator. Each dust collection fan picks dust laden air from respective area through different branches of the dust collection pipings. It is conveyed through ducts under negative pressure to the cyclone where the heavier particles are removed by the cyclonic action. The remaining dust particles are removed in a ventury scrubber by process water. After scrubber a mist eliminator is provided to remove mist before it goes to the dust collection fan and to the stack. Scrubber water is collected in a sump from where it is pumped to thickener tank and mixing tank.

COMPRESSED AIR SYSTEM

Compressed air system can be sub-divided in to two systems; 1) Plant air system 2) Instrument air system

Plant Air System

This system consists of a compressor and an air receiver supplies compressed air to deferent part of the plant. Plant air is used for N.G shut off valves, silo and fines bin seal valves, product dust and fines bin bottom gates, dust collection sump and classifier sump agitation and for other general use. Plant air is having a back-up supply from the centralized compressed air system located near air separation plant.

Instrument Air System

This system consists of a compressor, oil separator, drier units and air receiver. Compressed air is dried and cleaned and used as instrument air. Instrument air is used for instruments located in different parts of the plant. The back-up to the Instrument air is coming from the centralized air system as well as D.R plant air compressor.

DE-SULPHURIZING SYSTEM
The purpose of this facility is to remove hydrogen sulfide ( H2S ) from the natural gas being used in D.R plant, by the stretford de-sulfurizing process. This plant consists two absorbers, one scrubber, two mist eliminators, one reaction tank, three oxidizers, balance pit, solution pumps, oxidizer blowers and a filter press. De-sulfurizing plant receives natural gas from the gas receiving station , having controlled the gas pressure at around 8.0 kg/cm2. This pressure is further lowered to 5.0 ~ 5.5 kg/cm2 in D.S and the gas is supplied first to a knock out pot where the condensates are removed. Then the gas enters the first absorber through the bottom, comes in contact with the stretford solution which is sprayed from the top of the absorber. The stetford solution absorbs H2S from the gas to as low as 1 PPM from around 3000 PPM. Natural gas comes out from the first absorber from the top, enters the second absorber and goes through the same process. After the second absorber, the gas is getting cleansed with water sprays in a scrubber and then supplied directly for D.R use. The stretford solution after H2S absorption, undergoes re-generation reactions in a reaction tank and three downstream oxidizers before being pumped back to the absorbers. The chemical reaction during this process are as follows;
H2S + Na2Co3 = NaHS + NaHCo3

( Hydrogen sulfide is absorbed by alkali ) Conversion of Sodium by sulfide to elemental sulfur;

2NaHS + 4NaVo3 + 4NaHCO3 = 2S + Na2V4O9 + 4Na2CO3 + 3H2O Na2V4O9 + 2Na2ADA + 2Na2CO3 + 3H2O = 4NaVO3 + 2Na2ADA-H2 + 2NaHCO3 2Na2ADA-H2 + O2 = 2Na2ADA + 2H2O

At first NaVO3 ( Sodium Meta-Vanadate ) reacts with NaHS ( Sodium Hydrogen Sulfide ) and produces elemental sulfur. Reduced sodium metavanadate ( Na2V4O7) is re-oxidized to NaVO3 by Na2ADA. The reduced ADA ( Na2ADA-H2 ) is re-oxidized to Na2ADA by air. Na2CO3 ( Sodium Carbonate ) or NaOH ( Sodium hydroxide ) can be utilized as the alkali for this process.

OXYGEN INJECTION SYSTEM

PURPOSE
For each 10C increase in bustle gas temperature, a Midrex plant can realize 1.5 ~ 2 % increase in production. In order to increase the temperature of bustle gas above the reformed gas temperature, oxygen is injected in to the reformed gas mixer .The oxygen will burn some of the combustibles in the reformed gas and raise the temperature. The facility to inject oxygen in to the process system is known as oxygen injection system. This is a modification introduced in the year 2003 and is on line since June 2003.The required oxygen is supplied by QASCOs oxygen plant. Oxygen is injected through 10 nozzles situated all around the mixer. The amount of temperature increase will be determined by the amount of oxygen injected. While the plant is on normal operation with oxygen injection system is ON, oxygen flow will be automatically modulated to maintain the set bustle gas temperature. During start up and shut down of oxygen injection system, the nozzles and upstream pipe lines are purged with purge gas, stored in an accumulator. The major parts of oxygen injection system are the oxygen injection skid located at the east side of reformed gas cooler, oxygen injection nozzle unit and the control system called as PCS-7 located in control room. Oxygen injection skid consists of a purge gas accumulator, oxygen pressure regulators, shut off valves, flow control valve, flow meters and the individual header solenoid valves. Purge accumulator is always stored with purge gas with a pressure of 13.0 bar. Before oxygen is introduced in to the bustle gas, the oxygen injection system piping is pre-purged for about 13~30 seconds , with purge gas stored in this tank. Similarly, after the oxygen injection system shuts down, intentionally or other wise, a post purge sequence is automatically initiated which also lasts for 13~30 seconds.

OXYGEN INJECTION SYSTEM

Oxide Coating System
The danger associated with higher bustle gas temperature operations is swelling and sticking of pellets forming clustering in the furnace. The sticking and swelling index of iron oxide can be enhanced by coating the pellet by lime, cement etc. In order to achieve the above objective, along with oxygen injection system, the facility of oxide coating is also incorporated. Lime addition facility is situated at oxide transfer conveyor area. The major parts of this system are; 1- Lime storage bin ( FL-F60 ). 2- Oxide coating storage bin activator ( FD-61 ). 3- Oxide coating slide gate ( SG-F63 ). 4- Oxide coating feeder ( FD-F62 ). 5- Oxide coating mixing tank ( TK-F63 ). Storage bin is having a capacity of 80m3. Bin is filled with lime directly from the truck by pneumatic method. Storage bin activator is nothing but a vibrating cone situated at bottom of the storage bin, in order to overcome the problem of arching, bridging and rat-holing and to establish a smooth material flow. Oxide coating feeder consisting of a positive flow, dry solids metering screw where lime discharge is precisely regulated by a multiprocessor controller on a weight-loss basis. The weight-loss principle for continuous weigh feeding requires periodic refilling of the feeders supply hopper, which is an automatic process. The bin activator, slide gate and oxide coating feeder are designed as a combined system, along with the weight feed controller. From the feeder, lime is discharged to a mixing tank where it is mixed with fresh water in a pre-set ratio. Solution will overflow on to the oxide and be distributed using a diffuser plate.

Transition Zone Natural Gas Injection System

This system also incorporated along with oxygen injection system. The purpose of this system is to utilize the residual heat in the furnace bed for achieving higher in-situ reforming and better carbon control. This system consists 8 injection nozzles fixed on the furnace body situated just below upper cluster breaker. Nozzles are fixed as a pair at each side of the furnace. For each set of nozzles, there is a natural gas supply line equipped with shut off valves, manual flow control valves and flow measuring devices. The main flow control valve controls the total natural gas flow to transition zone. The nozzles and upstream pipe lines are purged on each start-up and shut of this system using a part of cooling zone gas.