Failure Analysis and Preventive Measure Proposition of Self-Flow Castable Blow Pipe of Blast Furnace Tuyere Stock for En
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ORIGINAL ARTICLE
Failure Analysis and Preventive Measure Proposition of Self-Flow Castable Blow Pipe of Blast Furnace Tuyere Stock for Enhancing Reliability Basudev Mishra1 • Prabodh Ranjan Padhee2 • Rakesh Kumar Singh1 Dibya Ranjan Sahoo3 • Shashank Mishra2
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Received: 9 February 2020 / Accepted: 8 June 2020 Ó The Indian Institute of Metals - IIM 2020
Abstract In this present study, the failure incidents of selfflow castable blow pipe of high volume blast furnace tuyere stock have been critically investigated. Based on failure analysis of failed blowpipes, possible preventive measures have been proposed. High hot blast pressure has been found to be the condition for occurrence of blowpipe failure. Hence, proper regulation of hot blast pressure is of utmost importance as a preventive measure. To analyse the cause of failure, after installation of blowpipe, the shell temperature is measured on a daily basis. It is observed that when the shell temperature crosses 350 °C, blowpipe jamming occurs. According to preventive step proposition, if the temperature crosses 350 °C and attains 480 °C, the blowpipes are advised to be replaced for maintaining the operation of blast furnace. This study has been done in high volume blast furnace where it is found that the impact of failure is immense with regard to productivity and safety. It has also been found that the compendium of this investigation can be replicated in other high volume blast furnaces and can also be extended to any low volume blast furnace. Keywords Tuyere stock Blowpipe Self-flow castable Blast furnace Iron making
& Rakesh Kumar Singh [email protected] 1
Research and Development Centre for Iron and Steel, SAIL, Ranchi, India
2
Rourkela Steel Plant, SAIL, Rourkela, India
3
Metallurgical and Materials Engineering Department, National Institute of Technology Rourkela, Rourkela, Odisha 769008, India
1 Introduction A blast furnace is a type of metallurgical furnace in which a counter current exchange type of chemical reaction takes place between the top burden (iron ore, lime stone, sinter) and bottom blown hot blast of air (enriched with oxygen and carbon monoxide) to produce molten iron [1–4]. For reducing the cost of production, PCI (pulverized coal injection) has been introduced in modern blast furnaces which decreases the coke rate by utilizing non coking coal. [3–5]. In the PCI technique, the pulverized coal is injected to the blast furnace along with hot blast through the blowpipes [6, 7]. The hot blast travels inside the blowpipe at a temperature higher than 950 °C with the simultaneous combustion of pulverized coal [7–9]. Deposition of ash from pulverized coal in the tuyere, erosion and the reliability of the blowpipe are significant factors, with respect to operation of blast furnaces having PCI technology [5]. The case study of this paper is performed to address the industrial problem of blast furnace-5 of Rourkela Steel Plant, SAIL. The basic parameters of blast furnace no.-5 are as follows: 1. 2. 3.
Working volume of 4060 m3 Mean out
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