Numerical Investigation on Cooling Strategies in a Commercial Blast Furnace Hearth

2004 ◽  
Author(s):  
Anil K. Patnala ◽  
Chenn Q. Zhou ◽  
Yongfu Zhao
Keyword(s):  
Blast Furnace ◽  
Cooling Water ◽  
Operating Conditions ◽  
Cfd Modeling ◽  
Dominant Factor ◽  
Furnace Hearth ◽  
Blast Furnace Hearth ◽  
Campaign Life ◽  
Parametric Effects ◽  
Flow Heat

A blast furnace is the predominant iron-producing process in the U.S. It is widely believed that the blast furnace hearth refractory is the most dominant factor affecting the campaign life of a blast furnace. The hearth, where the liquid metal is collected, is made of carbon bricks. Cooling water is normally applied to the outside wall of the hearth. Wear of the carbon refractory occurs primarily because of erosion, which is related to the operating conditions of the hearth, such as the liquid flow in the hearth and the heat duty to the walls. Evaluation of fluid flow, heat transfer, and erosion patterns in the hearth are critical to the extension of the campaign life of a blast furnace, leading to the increase of productivity and saving of costs significantly. Advanced computational fluid dynamics (CFD) modeling techniques make it possible for providing detailed information on furnace conditions and parametric effects on performance. In this research, the blast furnace No. 13 at U.S Steel has been simulated using a comprehensive CFD model. The model was validated using the temperatures measured by thermocouples in the wall refractories of the furnace. The effects of cooling water on the temperature distributions as well as erosion patterns were evaluated. The results provide useful information for the furnace operations.

Numerical Investigation of Cooling Strategy for Reducing Blast Furnace Hearth Erosions

2005 ◽  
Author(s):  
Fang Yan ◽  
Chenn Q. Zhou ◽  
D. Huang ◽  
Pinakin Chaubal
Keyword(s):  
Blast Furnace ◽  
Metal Flow ◽  
Cooling Water ◽  
Hot Metal ◽  
Furnace Hearth ◽  
Cooling Water Temperature ◽  
Cooling Strategies ◽  
Temperature Distributions ◽  
Blast Furnace Hearth ◽  
Campaign Life

Hearth wearing is the key limit of a blast furnace campaign life. Hot metal flow pattern and temperature distributions are the two key variables to determine the rate and style of the hearth wearing. There are several strategies to control and reduce the hearth erosion, such as changing cooling water temperature and changing the heat transfer coefficient. In this paper, both cooling strategies are investigated using a comprehensive computational fluid dynamics (CFD) code, which was developed specifically for the simulation of blast furnace hearth. That program can predict the liquid flow patterns and temperature distributions of the hot metal as well as temperature profiles in the hearth refractory materials under different conditions. The results predicted by the CFD code were compared with actual industrial operation data. The cooling strategies are evaluated based on the energy analysis and effect on the hearth erosion.

CFD Modeling and Analysis of The Flow, Heat Transfer and Mass Transfer in a Blast Furnace Hearth

2011 ◽  
Vol 82 (5) ◽  
pp. 579-586 ◽  
Author(s):  
Bao-Yu Guo ◽  
Ai-Bing Yu ◽  
Paul Zulli ◽  
Daniel Maldonado
Keyword(s):  
Heat Transfer ◽  
Mass Transfer ◽  
Blast Furnace ◽  
Cfd Modeling ◽  
Furnace Hearth ◽  
Modeling And Analysis ◽  
Blast Furnace Hearth ◽  
Flow Heat

CFD Modeling of Skull Formation in a Blast Furnace Hearth

2012 ◽  
Author(s):  
Dong Fu ◽  
Yan Chen ◽  
Chenn Q. Zhou ◽  
Yongfu Zhao ◽  
Louis W. Lherbier ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Blast Furnace ◽  
Cooling Water ◽  
Operating Experience ◽  
Protective Layer ◽  
Cfd Modeling ◽  
Furnace Hearth ◽  
Cooling Water Temperature ◽  
Blast Furnace Hearth ◽  
Skull Formation

The formation of the protective layer of solidified metal (skull) is critical to the blast furnace hearth operation. Enhancement of the formation of the skull layer could extend the hearth lining life and blast furnace campaign. In this paper, a CFD model that consists of solidification, flow, heat transfer has been utilized to simulate the skull formation phenomena in a blast furnace hearth. The heat transfer characteristics and temperature distribution of the skull and refractory brick has been investigated. The simulated results are comparable with operating experience of U. S. Steel blast furnaces. Parametric study includes lining property and structure, cooling water temperature and flow rate, hot metal (HM) temperature and the production rate, as well as cast practice.

Computational Fluid Dynamics Analysis of 3D Hot Metal Flow Characteristics in a Blast Furnace Hearth

2010 ◽  
Vol 2 (1) ◽  
Author(s):  
Chenn Q. Zhou ◽  
D. (Frank) Huang ◽  
Yongfu Zhao ◽  
Pinakin Chaubal
Keyword(s):  
Fluid Dynamics ◽  
Computational Fluid Dynamics ◽  
Blast Furnace ◽  
Metal Flow ◽  
Measurement Data ◽  
Operating Conditions ◽  
Hot Metal ◽  
Furnace Hearth ◽  
Blast Furnace Hearth ◽  
Computational Fluid Dynamics Analysis

The campaign life of an iron blast furnace depends on hearth wear. Distributions of liquid iron flow and refractory temperatures have a significant influence on hearth wear. A 3D comprehensive computational fluid dynamics model has been developed specifically for simulating the blast furnace hearth. It includes both the hot metal flow and the conjugate heat transfer through the refractories. The model has been extensively validated using measurement data from Mittal Steel old, new IH7 blast furnace and U.S. Steel 13 blast furnace. Good agreements between measured and calculated refractory temperature profiles have been achieved. It has been used to analyze the velocity and temperature distributions and wear patterns of different furnaces and operating conditions. The results can be used to predict the inner profile of hearth and to provide guidance for protecting the hearth.

Aspects of blast-furnace hearth maintenance in the smelting of a titanomagnetite charge under unstable operating conditions

Metallurgist ◽  
1998 ◽  
Vol 42 (3) ◽  
pp. 86-90
Author(s):  
G. G. Gavrilyuk ◽  
Yu. A. Lekontsev ◽  
S. D. Abramov ◽  
V. A. Zavidonskii
Keyword(s):  
Blast Furnace ◽  
Operating Conditions ◽  
Furnace Hearth ◽  
Blast Furnace Hearth

Development and Application of Online Monitoring System for Blast Furnace Hearth and Bottom

2011 ◽  
Vol 317-319 ◽  
pp. 1289-1294
Author(s):  
Hong Ming Long ◽  
Jia Xin Li ◽  
Ping Wang
Keyword(s):  
Blast Furnace ◽  
Monitoring System ◽  
Online Monitoring ◽  
Operating Conditions ◽  
Transfer Model ◽  
Furnace Hearth ◽  
System A ◽  
Campaign Life ◽  
Residual Thickness ◽  
Online Monitoring System

The campaign life of a modern blast furnace is determined by the residual thickness of the refractory in the hearth and it can be prolonged by adjusting operating conditions based on a reliable online monitoring system. A new methodology, combining a 1-D heat transfer model and a statistical model to predict the inner profile and the refractory lining of a blast furnace during operation respectively, was established in this study. The application of the developed online monitoring system on a blast furnace was used to demonstrate the effectiveness of the models.

Occurrence state and Behavior of Carbon Brick Brittle in a Large Dissected Blast Furnace Hearth

2021 ◽  
Author(s):  
Ziyu Guo ◽  
Jianliang Zhang ◽  
Kexin Jiao ◽  
Yanbing Zong ◽  
Zhongyi Wang
Keyword(s):  
Blast Furnace ◽  
Furnace Hearth ◽  
Blast Furnace Hearth ◽  
Occurrence State ◽  
And Behavior

A Model to Simulate Titanium Behavior in the Iron Blast Furnace Hearth

2010 ◽  
Vol 41 (4) ◽  
pp. 876-885 ◽  
Author(s):  
Bao-Yu Guo ◽  
Paul Zulli ◽  
Daniel Maldonado ◽  
Ai-Bing Yu
Keyword(s):  
Blast Furnace ◽  
Furnace Hearth ◽  
Blast Furnace Hearth ◽  
Iron Blast Furnace
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