ap TATA ‘TATA STEEL Adoption of Shot Crete Technique for Restoration of Throat Profile at Tata Steel Mr. Uttam Singh Vishakhapatnam Chief I’ Blast Furnace Date: 05" Nov’09‘F’ Blast furnace was upgraded from 0.5 Mtpa to 1.0 Mtpain Fy’02 *Stock house screening and ration +A flat cast ho holes 60 deg apart conveyor e with two tap *Free standing structure and dense plate cooling system ft water. + First compact bell less top + First 100% castable flat ca: TATA TATA STEEL Working Volume 1576m* Useful Volume 1831m* Hearth Diameter 9200mm Number of Tuyeres 24 Number of Tap holes 2(60 deg apart) Maximum Blast Hn Pressure can Maximum Top a 4 Pressure GeO Maximum Blast Ronen) Temperature ‘Top Charging PW compact Bell-less Top Furnace Cooling Dense plate cooling System system Hot Stove 3nos. Internal typePYF BFPerformance a TATA STEEL Production Problem of Throat Erosion + 400000 som + 300000 + aon sie ‘soon +p00000 | 555 soo00 ol sna0n 8 5 8 g 5 2 8 te rz = E = r z Coke rate sr seo LS ot 530 10 ar 490 $68 0 486 . = a a a0 iPYF BFPerformance urn "TATA STEEL Coalrate Problem of Throat Erosion io bat ae Tor 100 oo a 80 70 i 80 7 * = " 4“ | 8 a 8 s 5 z Z . ze = = : S E Fuslrate 00 ee sap |__2 8 80 oo a er 60 . 560 "2 seo 500 520¢ Stack area brick was not in its good condition and the bottom rows of stock shield plate had protruded inside the furnace. her permeability resistance it e upper part since Januar ¢ Stock line was lowered Damaged ; . Armour Fuel rate i & production de e Plateschanism of Dislodging ‘TATA STEEL 8 Rows of Throat Armour Plate Uru tee) Pereum aac Pen enc mena e| Pree ec lla) eC cheers ere) ETC rete ae ec STE TyDetails of ‘F’ BF throat Armour Element Condition of Armour Plates * Row 1, 2,3 * Row 4 * Row 5 * Row 6, 7& 8 : Plates were in good condition and fixed in position : Plates warped, but in fixed position : Plates were badly buckled : Plates were protruding and dislodgingStack Gunning on 25" May 2006 Damaged stock shield plates (W side) Damaged stock shield plates (S-side)TATA \TA STEEL After 89 days of Operation on 25% Aug 2006 No gunning material Stock shield plate started coming Gunning material has een come out and lower three layers of stock shield plate also started. dislodgingThroat Condition as on 23"! Feb 2009 Throat condition (Lastfiverows of stock ‘Zevo Stock ine level shield plate badly damaged Fig.3 Profile of wall, v after 4m stock lineap RGF OF Mised Layer Formation ‘TATA STEEL + When upper part of furnace is intact, burden particles descend while maintaining the ore and coke layer structure (1a). icles nea the furnace wall moves locally towards the the wall (01 + In case of wall erosion, the pa wall and form a mixed layer(1c), causing incrasced eae val Deformation of layer " ao » No deformation ‘Small deformation ‘structure and formation ost * 2 fat oflayersvuctire of yerstxttre of med yer aot gel ae fot Se Ses) \Fie i see 3 wat i ost ! ! od i fod So oa a) Noer ) Wall erosion ¢) Wall erosion eke B00 880 so (shaft ance (call change, (orge change, Distace from aera deg) shat sng = 36 deg.) (hrc dimensional cold mode experiment) 2+ Retationsh {ween wall erosion condition and gas Mow (Tee dimensional cold model experiment) tirana the per shan sr Sento = 0120, coke: t6mm ‘Mixed LayerFormation leadsto the building up of Scaffold because of preferentialmeltingin that region between wall eresion condition 80/20, coke: 4-6mm)Minporfance oF Blast Furnace Throat Profile |.7°", + Unstable Furnace Operation « Lower production + High Fuel Rate ¢ Formation of mixed | wall ayer which will cause higher gas velocity at + Formation of scaffold and higher pressure drop at top portion of furnace + Excessive wear of lining by uncontrolled gas flow + High temperature gas flow causing further damage to the throat. ¢ Unstable distribution makes the higher gas velocities at the wall and take away the fines. Fines are not loaded at the wall.Before Shotcreting Hanging Spell Lowered Stock line Up to 1.5 Meter After Shotereting Improved Spell [Production (Tonnes per day) 4000) 3900) 3700 fA ; pry ela RP . 3600 bal ‘atin ial iy * t zany ft TH 7 3300 T y 1 i 3200 : B 8 & &§ &| & & & & &/ 8 & 8 5 8 2 4 fs f ge ale ee #00 Fuel Rate (Kgithm) 590 t Ly ? i f Bi 5e0 + t Re Rs 5] [ae 940, 530, Be 520 s &§ § § & 5 § B 3 § 8 TATA ‘TATA STEELIdeat Repair from out side of the frnace Idea 2 Repair from inside the furnace by conventional method TATA TATA STEEL Idea3 Shotereting * Drill pipe branches for Armour Plates in two rows from outside «Remove damaged plates fron outside + Gun the armour area f better surface + Place new plates fro over old plates n top + Fix one row of armour plates by tie rods and chains + Fix one row of staves below armour plates * Shutdown Duration is 20 days * Installation of Movable platform inside furnace + Remove all the existing plates and ribs + Provide refractory lining below & behind staves + Fix single row water cooled refractory lined cast iron staves +Total Shutdown duration required was 30 days. + The dense structure of castable material having high abrasion and impact resistance, results in life of throat area improved * Total Shut down duration required was estimated around 48 hrs.s. | Conventional Replacingfrom | Shotcreting (short No. | Method to Change | Outside the Furnace | term repair) 1 Unsafe to work as it is * Loosening sauctural * Castableis transported very difficutte ensure | strength through diemixer to gasfiree atmosphere + Total no'sopening the application site required is 36. + Inside the furnace application is done by robot. 2 | Burdentobeblown | Holetobedonein Safe processand furnace down up totuyerelevel | running furnace tobe blown down only up and cappingmeburden | notsate. to10m. with refractory concrete. 3 | Thestare up processin | High down ame of20days | Thefurnacestart up and this case is slow. stabilization is smooth 4 [Down timeotrepairis | Removalof debrisis not | Maximum 36hnsof shat 30 days whichis v high. possible which m: somepr downisrequired.+ Process used for installing refractory castable over old refractory surface. + Defined by American Shotcrete Association as, “Mortar or concrete pneumatically projected at high velocity onto a properly prepared surface.”. + Dense low cement castable is mixed with water and other liquid binder into a mixer machine and the mix is pumped and finally sprayed on the old refractory surface under high pressure, to develop refractory thickness * Mullite based Low cement castable is used in shotcreting. + Selection criteria for material * Excellent abrasion resistance towards descending blast furnace burden. * Thermal shock resistance. * Resistance to CO attacks (CO disintegration). + High strength in low and medium temperature (250 to 850 deg C) + No shrinkage within the application temperature. * Good adhering / stick ability with old refractory surface. + Durability.Salient Points of Shotcreting ace ba ‘TATA STEEL + Stock line was lowered to 10 meters after charging total 70 tons of extra coke. Coke rate was increased to 700 Kg/Thim. * Total 25 m3 water was used for blowing down. Stock line at the time of w/o was 9.85/ 10.0 meters. + For the purpose of sealing the burden last three skips before wind off metallic 100% sinter was charged. The shotcrete equipments, machine, hose pipe, pod, hoist, control panel ete. were placed in cast house and in furnace top. The arrangements are shown Erection of shot Crete pipe, hoist, checking of machine etc.* Shotereting started at 4:00 AM and finished at 11:30 AM on 11.04.08 + Total shotcrete quantity was 60 tons. Average shotcreting rate was 8 tons per hour. *Si in maintaining zero stock line of the furnace. art up was smooth, after start up and stabilization there was no problem Inserting pod, lance fixing, Shotereting in progress (activity at Shotereting in progress accelerators preparation ete cast house)TATA \TA STEEL * Shotcreting shut down on 10" April 708. * Since first time such type of activity we chart has been prepared. planned, a detailed Dextlr a |e ee [S/S EEE E\EIE EE E\E|= = |= |Z |= |z EZ IEE (RES 2 2 (E SN» ok Dipti vey (2/215 13 (S |S (ES S/S 2 |S |S/S/8 5/5 ISIS |S (ISIE (SSS EG os ES EECERS ESBS Sa SESE REEF ES Ee as Be Erle eles ofa fz] 3 as fo ]z [a | [so\r1|s2|13[ 19151017 [1210 ola fea lasfe aslo lar lee Soa 3) depkgite ao | [a fSe eng arab be a: ee 200 |1 | 3 | BRO 3 eeimigular cover opetare | 3.09 | 2 | 5 | nas ranaring oft Above ~q:_petent 300 |2 | 5 | msc aig ie onto yuan 2m 3,4] 6 | BRO «pai orem [smo [5 [7 [ro ig OU ping + fase im fe |e | nro SaeRy aT $_beon am > {>| aro long 0 oft sm {s [10 | aro 10 Pakngoatstotereting we |'2m [9 [11 | pro 11 Parmagarcorercorig [am [iol | so 12 _Pefbng of both ABP 60/9 113 | so tz Amand cor 5 Si ara etePPPF—F REIS GF Shotcreting BeforeTATA \TA STEEL Itwas decided to do shotcreting in every 6 months. In four months shoterete material were worn off. + Furnace again started seeing irregular g: pattern. + Furnace was run with higher stock line till next Shotcreting. F BF Production = After Shotcreting ee Shateretin[meee] FEFRROMUCTON Bra (ears) sistent Production achieved after doing shotcreting in every 4 months