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Efficient Optimization of BOF-dedusting

Conference Paper · October 2014

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EFFICIENT OPTIMIZATION OF BOF-DEDUSTING

Kersten Marx
VDEh-Betriebsforschungsinstitut GmbH, Düsseldorf, Germany
Abstract
Secondary off-gas cleaning systems for BOF-dedusting are normally installed to evacuate
the hot fumes produced during the converter operation steps scrap charging, hot metal
charging, steel tapping and slag dump. Environmental issues are requiring efficient dedusting
systems. Also the capital costs as well as the operation costs for dedusting systems in steel
industry are high, so that an optimum design with regard to an economical operation is very
important.
To fulfil these requirements VDEh-Betriebsforschungsinstitut further developed measuring
methods and simulation approaches to investigate actual or planned plant configurations in
order to improve their performance. Gas composition, dust concentration, temperature and
flow velocity were continuously measured for different process phases to acquire boundary
conditions for the model trials and the numerical simulation. The fume flow rate was deter-
mined with a new method (Structural PIV). The relevant dedusting facilities are studied with
three-dimensional isothermal physical models. Additionally flow and temperature conditions
as well as the fume propagation were simulated using a computational fluid dynamics (CFD)
programme. Necessary suction flow rates can be reduced by fume suppression techniques.
A possible technique is the addition of inert gases in the region of the melt surface.
As a result of this investigation measures are provided enabling improved fume capture effi-
ciency with minimized suction flow rate, leading to improved working conditions in the plant,
prevention of fugitive emissions from roof vents and compliance with environmental stand-
ards. These measures were successfully implemented in several steel plants.
Introduction
The filling of hot metal in converters is accompanied by the emission of large quantities of hot
gases and dust. Installing auxiliary hoods requires special adaptation of the design and pre-
cise positioning. Large amounts of energy are wasted, if hood geometry and the fume evac-
uation volume do not fit properly to the different operating conditions. Studies in two steel
plants were performed to compare and optimize different types of suction hoods (with and
without vortex) and to develop effective techniques for fume and flame suppression.
1. Study at Steel Plant A
1.1 Measurements in the plant
In Steel Plant A no extraction hoods for secondary dedusting were installed in the direct vi-
cinity of the two converters before the study. In contrast to nearly all other steel plants the
normal practice in Steel Plant A at the time of the study was to charge scrap after hot metal
in order to decrease the wear of the converter lining. When hot metal is charged into the
empty converter vessel the fume emissions are moderate. But if scrap is charged after hot
metal a flash develops, which is substantially loaded with dust. The chute works like a chim-
ney, so that in the worst case the flames can penetrate deep into the bay.
The conditions in the flame during scrap and hot metal charging are quite unknown, because
measurements directly in the flare are very difficult. Especially no data were available for the
reversed charging sequence (“first hot metal, then scrap”) In order to acquire boundary con-
ditions for the model trials and the numerical simulation the gas concentration (O 2, H2, CO2
and CO), the temperature with/without radiation and the flow velocity were continuously
measured directly on height of the trolley upper edge in a distance of 750 mm of the trolley
wall. Additionally the dust concentration was measured for different process phases.
The temperature including the influence of radiation has been measured with a thermocou-
ple, which was directly exposed to the flame. For the determination of the temperature with-
out radiation a thermocouple was installed in a water-cooled probe. The ceramic tip of the
 2

probe, which shields the thermocouple, has not been cooled. With the help of a vacuum
pump the flue gas from the flare is sucked off by the probe and thus its temperature was
measured and its composition was analysed in the subsequent measurement equipment
simultaneously. For the determination of the flow velocity a water-cooled cylinder probe was
used. For the dust measurement a separate probe was used, which was not cooled. With the
help of a vacuum pump the flue gas from the converter has been sucked off by the probe
during the studied process phase and the dust was separated on a filter paper, which has
been changed after every trial.
When hot metal is charged after scrap, only one peak in the measured temperature curve
occurred, see Figure 1. The maximum temperature during hot metal charging was about
1100°C.
1400
1300
1200
1100
Temperature in °C

1000
900
800
700
600
500
400
300
200
100
0
17:55:00 18:00:00 18:05:00
Time

Figure 1: Measured temperature for charging sequence: 1. Scrap, 2. Hot metal

When hot metal was charged before scrap, only a small peak in the measured temperature
curve occurred during hot metal charging. An additional higher peak occurred during the
subsequent scrap charging. The maximum temperature during scrap charging was about
1300°C, see Figure 2.
1400
1300
1200
1100
Temperature in °C

1000
900
800
700
600
500
400
300
200
100
0
13:15:00 13:20:00 13:25:00
Time

Figure 2: Measured temperature for charging sequence: 1. Hot metal, 2. Scrap

When hot metal was charged after scrap, only one peak in the measured curves for combus-
tible gases occurred. The maximum concentration of CO and H2 was lower than 3 Vol.-%,
see Figure 3.
 3

12
CO
10 CO2
Concentration in Vol.-%

H2
8

0
17:55:00 18:00:00 18:05:00
Time

Figure 3: Measured gas composition for charging sequence: 1. Scrap, 2. Hot metal
When hot metal was charged before scrap, only a small peak in the measured curve for CO2-
concentration occurred during hot metal charging. The concentration of combustible gases
was not significant during hot metal charging. But additional higher peaks occurred during
subsequent scrap charging. The maximum concentration of CO exceeded 10 Vol.-% and the
maximum concentration of H2 was about 7 Vol.-%, see Figure 4.

12
CO2
CO
Concentration in Vol.-%

10
H2
8

0
13:15:00 13:20:00 13:25:00
Time

Figure 4: Measured gas composition for charging sequence: 1. Hot metal, 2. Scrap
1.2 Development of improvements
The flow, temperature and concentration field in a representative part of the steelwork for the
process phases “hot metal charging”, was simulated using a Computational Fluid Dynamics
(CFD) programme. Additionally the influence of a cover on the scrap chute on the efficiency
of the suction hood was determined. The flames originating from scrap charging penetrate
deep into the charging bay. The corresponding calculated temperature field for this case is
given in Figure 5a.
 4

Temp. (K)

a) b)

Figure 5: Calculated temperature field during scrap charging,

a) before optimization
b) with secondary dedusting and cover on scrap chute (b)
For this case the flow velocity out of the converter vessel is so high, that the flames hardly
can be captured by a charging hood. But if the scrap chute is covered, the flames are di-
rected to the enclosure and the greatest part of the fume can be captured by the hoods, see
Figure 5b.
It is indispensable to provide the scrap chute with a cover, if an almost complete capture of
the fumes during scrap charging should be achieved without changing the charging se-
quence. Therefore additional operational trials were performed, in which the scrap chutes
were equipped with a provisory cover, see Figure 6. For the observed charges the emissions
were very low during scrap charging with covered chutes. Obviously a great part of the rising
combustibles is sucked into the primary dedusting hood before they can react with the ambi-
ent air. The preliminary trials with the covered chutes were very promising concerning opti-
mized fume capture efficiency.

Figure 6: Scrap charging in hot metal, scrap chute without (left) and with cover (right)
 5

2. Study at Steel Plant B

2.1 Documentation of the present practice
At Steel Plant B the primary off-gas system accomplished the secondary ventilation during
charging via a by-pass function. However, the fume capture performance of the charging
hood was very poor during converter charging and was not carried out at all during the blow-
ing phase. During blowing and tapping a third off-gas system on the tapping side was acti-
vated. The emissions captured by the charging hood and the primary off-gas system were
cleaned by a venturi scrubber. The tapping hood was connected with a fabric filter. BFI has
carried out a plant observation in order to acquire boundary conditions for the numerical and
physical modelling.
In order to document the conditions at the converter video photographs were taken from dif-
ferent views. Plume photography has proven an effective method of estimating buoyant
plume volumes for hot emissions sources. BFI uses advanced image analysis software
called Structural PIV for the quantification of fume flow rates. This methodology differs in
several points from the classical PIV (Particle Image Velocimetry) technique. Instead of using
a laser for creating a light sheet, white light or even day light is sufficient. The second differ-
ence is the seeding method used. PIV is working with tracer particles. Structural PIV on the
other hand works with small structures for example in smoke clouds. The analysis of images
of smoke clouds is done by ensemble correlation averaging, which makes it possible to re-
ceive a mean flow field with a sufficient high signal-to–noise ratio. The advantages of Struc-
tural PIV are that it can be used on full-scale objects in the plant, less safety precautions are
necessary and the equipment is cheaper. Figure 7 shows a determined flow field for the pro-
cess phase “blowing”.

Figure 7: Flow field determined with Structural PIV (velocity vectors and magnitude of ver-
tical component in m/s) in fume emitted during blowing phase of the converter
 6

2.2 Comparison of different charging hood types

Several hood types for the secondary off-gas system were studied. Figure 8 shows a sketch
of the old charging hood at Steel Plant B. In this hood a vortex is generated.

Figure 8: Geometry of the old charging hood

Figure 9 shows the geometry of an optimized hood.

Figure 9: Geometry of the optimized charging hood

The process phase “hot metal charging” was calculated for the old hood with the planned
flow rate of at least 750 000 m³/h (S.T.P.) through the charging hood. In order to take into
account also extreme reactions during hot metal charging and to have a better comparison of
the efficiency of the different hood types, it was assumed that fume leaves the converter ves-
sel with a velocity of 32 m/s. In Figure 10 the calculated velocity field in the central plane of
hoods are plotted. The flow velocities are very high for the vortex type hood because the
swirl in the hood produces an additional circumferential velocity component in the hood. This
leads to a high pressure loss. In the optimized hood the velocity values are moderate, no
detachment and recirculation of the flow can be observed.
 7

Velocity
(m/s)

Figure 10: Calculated velocity field during hot metal charging, vortex hood (top) and opti-
mized hood (bottom)

a) b)

Figure 11: Calculated fume propagation, hot metal charging

a) old hood b) optimized hood
In spite of the high velocity values in the vortex hood, complete fume capture is not achieved,
see Figure 11a. So this hood geometry could not be recommended for the planned flow
rates. The fume capture efficiency rises significantly with the optimized hood. Figure 11b
shows the corresponding calculated fume propagation for a flow rate of 750 000 m³/h
(S.T.P.) through the charging hood. Now the fume can be captured completely during hot
metal charging.
 8

2.3 Fume suppression

The basic idea of fume suppression is to eliminate contact of the liquid metal and atmospher-
ic oxygen. Fume suppression with injection of CO2 during hot metal charging was tested in
further trials. Liquid CO2 was stored in an insulated pressurized tank (20 bar, -20°C) on a
road tanker. Lances (snow tubes) were constructed and built, in which the liquid CO2 was
expanded through a nozzle and a jet of gas and CO2-crystals (snow) was discharged into the
converter vessel. The CO2-snow sublimates to CO2-gas, when it is heated up. Outside the
dog house a scaffold was put up on the 10 m-level. A lance was inserted through a hole in
the dog house wall and was moved with a special developed manipulator. The road tanker
was placed in a save place between the converters on 0 m-level. Figure 12 shows the instal-
lation of equipment for fume suppression.

Figure 12 Installation of equipment for fume suppression

Normally brown smoke is produced during hot metal charging. During injection of CO 2 with a
lance of 80 mm diameter in the flames a white fog was rising and the flames were brighter.
Figure 13 shows the conditions without and with inertization in comparison.

Figure 13 Fume and flame formation without (left) and with (right) CO 2-injection
(360 kg/min)
 9

In spite of the strongly restricted available space for a charging hood at Steel Plant B it was
foreseen to realize a suction flow rate of up to 1 000 000 m³/h (STP). Therefore a hood ge-
ometry had to be developed exclusively for these geometrical boundary conditions.
In Figure 14 the calculated temperature field in the symmetry plane of the converter is plot-
ted for the process phase hot metal charging for a suction flow rate of 1 000 000 m³/h (STP).
It can be seen, that cold false air is entering the hood from the enclosure, but the fume is
captured completely. Figure 15 shows the calculated fume propagation for 1 000 000 m³/h
(STP) suction flow rate.

Primary system: 0 m³/h

Charging hood: 1 000 000 m³/h
Fume velocity converter: 32 m/s

Figure 14 Calculated temperature field (K), hot metal charging, optimized planned hood,
max. suction flow rate

Primary system: 0 m³/h

Charging hood: 1 000 000 m³/h
Fume velocity converter: 32 m/s

Figure 15 Calculated fume propagation, hot metal charging, optimized planned hood, max.
suction flow rate
 10

Figure 16 shows the installed new charging hood above the converter during blowing.

Figure 16 Converter with new charging hood during blowing

The performance of the hoods verified the results of the numerical simulation. The new
hoods allow nearly complete fume capture during all process phases. Figure 17 shows the
fume capture during scrap and hot metal charging for a suction flow rate of about 750 000
m³/h STP.

Figure 17 Fume and flame capture with the new charging hood during scrap charging (left)
and hot metal charging (right)
 11

The new secondary dedusting system at Steel Plant B is now independent from the primary
system and the charging hoods were constructed based on the findings of the project. A
moveable skirt is used to close the gap between primary hood and converter mouth during
blowing. The new charging hoods allow nearly complete fume capture during all process
phases. From preliminary results can be estimated that it captures about 720 t of dust per
year. So a significant improvement of the working conditions can be expected.
3. Conclusions
Measurements, observations and operational trials in the plant, physical model trials and
calculations with a computational fluid dynamics programme were performed to provide the
necessary basic information for planned and existing secondary dedusting systems. It can be
concluded that model trials and numerical simulation are important powerful tools for the op-
timization of dedusting systems. Possible optimizing measures can be evaluated already in
the planning stage and the results can be transferred to the plant with good success. With
these tools BFI developed effective solutions to optimize dedusting systems for a great num-
ber of BOF shops.
Efficient charging hoods for small available space were developed and optimized by physical
model trials and numerical simulation. The simulation tools are adequate to study and com-
pare different types of suction hoods. The boundary conditions for the simulation can be
gained by video documentation (plume photography and image analysis with Structural PIV)
as well as measurements in the plant. A flare during scrap charging can be suppressed by a
cover on the scrap chute. The method for fume suppression during hot metal charging with
inert gases is expensive but probably applicable especially for small or medium sized con-
verters with weak exhaust systems. The new secondary dedusting system at Steel Plant B is
now independent from the primary system. The hoods, which were constructed based on the
findings of the project, have a very good performance.
The knowledge gained can be used within the steel industry to provide cost-effective emis-
sions reductions on the majority of BOF shops [1-5].
4. Acknowledgement
The work for the study at Steel Plant B was carried out with a financial grant from the Re-
search Fund for Coal and Steel of the European Union (RFCS Contract Number RFSP-CT-
2007-00045). The author wants to thank the staff of both steel plants for the good collabora-
tion as well as the Research Fund for Coal and Steel for the financial support.
References
[1] Marx, K.: Efficient optimization of dedusting systems. 27es Journées Sidérurgique Inter-
nationales 2006, December 14-15, 2006, Paris, France, pp. 154/155
[2] Marx, K.; Rödl, S.: Efficient optimization of steelplant dedusting. The 6th European Ox-
ygen Steelmaking Conference - Stockholm 2011, Programme No. 7-1
[3] Marx, K.; Rödl, S.: Efficient optimization of steelplant dedusting. Stahl und Eisen 132
(2012) No. 6, pp. 61-71
[4] Marx, K.; Rödl, S.: New approaches for efficient dedusting of basic oxygen furnaces.
Journées Siderurgiques Internationales - Paris 2012, Session 2
[5] Marx, K.; Wollenberg, M.: Development of effective dedusting of converters by innova-
tive concepts and constructive optimisation (Bofdedust) in: Report of the Commission
of the European Communities - EUR, Research Fund for Coal and Steel series, Lux-
embourg/Office for Official Publications of the EC (http://bookshop.europa.eu), Report
EUR 25907 EN 2013

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