2016-Sustainable Industrial Processing Summit
SIPS 2016 Volume 6: Yagi Intl. Symp. / Metals & Alloys Processing

Editors:Kongoli F, Akiyama T, Nogami H, Saito K, Fujibayashi A
Publisher:Flogen Star OUTREACH
Publication Year:2016
Pages:480 pages
ISSN:2291-1227 (Metals and Materials Processing in a Clean Environment Series)
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    Numerical Simulation of Hearth Cooling during an Extended Blast Furnace Shutdown

    Xuefeng (John) Dong1; Paul Zulli2; Mark Biasutti2;
    1, Kensington, Australia; 2BLUESCOPE LTD, Port Kembla, Australia;
    Type of Paper: Regular
    Id Paper: 44
    Topic: 3


    The extent of hearth cooling is of paramount importance in determining the feasible duration of an extended blast furnace maintenance shutdown. Traditionally, measured refractory temperatures at the hearth side walls and pad are used to indicate the extent of hearth cooling during a shutdown. However, if the temperature trend is unusual, i.e. it does not follow any historical records, it is difficult to predict realistic hearth conditions through the refractory temperature alone, which generates uncertainty during the furnace shutdown. In this respect, numerical simulation of hearth cooling may be very helpful in providing detailed insight into the internal condition of the hearth including liquid bath and hearth refractory. In this study, based on a solidification front tracking approach, a transient numerical model had been established considering the effect of solidification enthalpy of liquid iron in both the coke bed and coke free layer to monitor the progress of hearth cooling in BlueScope Ltd’s Port Kembla No. 5 Blast Furnace. The model was firstly verified by comparing the refractory temperature to the calculated data during shorter duration furnace shutdowns (typically 1-2 days). It was then applied to estimate the hearth condition in an extended shutdown period (typically, 5-6 days). The calculated refractory temperatures were reasonably matched with the measured data over the extended shutdown period. In particular, the mushy zone (defined in terms of a temperature range around the 1150ºC isotherm) was tracked – this allowed visualization of the temporal variation of refractory temperatures and the extent of liquid bath cooling during a number of shutdowns, providing useful guidance for furnace engineers. Additionally, the model can be applied more broadly to monitor hearth conditions, such as in the case of an abnormal stoppage of the furnace.


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    Cite this article as:

    Dong X, Zulli P, Biasutti M. Numerical Simulation of Hearth Cooling during an Extended Blast Furnace Shutdown. In: Kongoli F, Akiyama T, Nogami H, Saito K, Fujibayashi A, editors. Sustainable Industrial Processing Summit SIPS 2016 Volume 6: Yagi Intl. Symp. / Metals & Alloys Processing. Volume 6. Montreal(Canada): FLOGEN Star Outreach. 2016. p. 69-84.