Optimization of Tap hole concept in JSPL BF#2

Shamshad Shaik, Amitava Sircar, A.K. Mukherjee.

Jindal Steel & Power Limited.
Abstract:

The new generation blast furnaces (BF) with large volumes operate at high top pressure,
increased blast temperature, injection of auxiliary fuels e.g. coal, natural gas at tuyeres
and oxygen enrichment of blast. This has resulted in an increase in tapping rate, tapping
temperature and tapping duration. Such changes have prompted radical changes in the
materials and applications of refractories in the BF cast house areas, particularly tap hole
clay.
Improvements in the properties of the tap hole materials use is to stop flow and maintain
controlled metal and slag flow have allowed the modern blast furnace to lengthen the time
of each tap, reduce the number of tappings per day, and increased the percentage of time a
furnace is tapping to insure smooth furnace operations. The hearth should be empty as
long as possible otherwise the permeability of the blast furnace will be adversely affected.
JSPL has started operating its BF#2 in October 2006. The blast furnace was designed to
produce 3600 mt hot metal/day and presently exceeds its performance level. The Coal
injection rate is about 140 kg/tHM with oxygen enrichment of the wind of about 4.5%.

In this article, emphasize has been given to the effect and behaviour of tap hole towards
the higher productivity of blast furnace.

1.0. INTRODUCTION

Tap hole is an outlet for hot metal produced in a Blast Furnace. Tap hole clays are used
for plugging of the Tap hole of Blast Furnace. The major objective of this material is not
only to plug the Tap hole but also to be drilled for the subsequent cast. The mud gun
pushes the Tap hole clay into Tap hole of Blast Furnace where it hardens and checks the
hot metal and slag from coming out of Blast Furnace.

The tap hole clay must consistently and safely perform the following:

• Good flow ability when pushed by the clay gun, to plug the tap hole.
• Cure within the tap hole during the plug to tap time but without shrinkage to ensure a
tight seal
• Be drilled in an acceptable time.
• Allow a stable, controlled melt stream at tap without spitting.
• Withstand erosion and corrosion by iron and slag.
• Provide a stable and controllable tap hole length.

1.1. The Tap hole Concept

Tap hole length is of vital importance for achieving a long blast furnace campaign. A
longer tap hole draws liquids from nearer the centre of the hearth, whilst a short tap hole
may promote peripheral flow leading to hearth wear in the characteristic ‘elephant’s foot’

Seminar on Efficient Iron Making & Support Initiatives November 2009

[1]. This is a function of the amount of clay injected and also of the erosion resistance of
the clay.
Along with the quality of clay, behavioural aspects of BF inside the tap hole region plays
a major role in contributing a proper tap hole concept.

The factors effecting are as follows:

Control of raceway

Analysis of drainage rate

Composition of metal and slag

Influence of hearth bottom and hearth side wall temperatures.

According to case study, JSPL BF#2 behaviour was considered. The main characteristics
of JSPL, BF # 2 are shown in Table I.

Table No.1. The main characteristic description of BF # 2

Start up date 13 Oct 2006

Useful Volume, m3 1681
Working Volume, m3 1462
Hearth diameter, m 8.4
Maximum Blast Volume, Nm3/min 2660
Maximum blast pressure, bar 3.2
Maximum Blast temperature, deg C 1250
Maximum Top pressure, bar 1.5
Charging system Bell-less Rotary Charging Unit
Number of tuyeres 20
Furnace cooling system Closed circuit Copper plate
Tap hole 2
Cast House 2, symmetrical
Slag Granulation Plant 1
Injection Pulverized coal injection
Stoves 3, Internal Combustion type

Control of raceway:

It is possible to infer the behaviors of mud mass in the furnace to a certain extent from the
phenomena observed in daily tapping operation. The mud gun mass pushed in the furnace
pushes aside coke in the furnace and forms a large rock bed. As the density of mud mass
is about 2200 kg/m3, lighter than the that of molten iron (Density: 6600 kg/m3) and slag
(2600 kg/m3) , the mud material floats up and doesn’t form a robust mud layer unless it is
pressed into coke gaps in the furnace. On the other hand, since the density of coke which
captures the mud material in the furnace is as light as 600 kg/m3, in the event that the load
which allows coke to land at the lower part of furnace decreases, the coke void ratio at the
mud front surface increases and the mud mass is easy to float up, and the tap hole length
decreases [2].
At the raceway section, the burden load is balanced with the ascending gas flow, the
actual load is less than that at the furnace centre section, and a high void ratio coke region
or free space are likely to be formed. Consequently, it is assumed that fluctuation of the

Seminar on Efficient Iron Making & Support Initiatives November 2009

tap hole depth is caused by fluctuation of load which allows coke to land on the lower
part of furnace, that is, fluctuation of raceway depth.
To cater decreased tap hole length as well as increased hearth wall temperature various
measures were implemented like closing of tuyere above the tap hole area, activate the
permeability of dead man to increase the centre working of the furnace and reducing the
tuyere diameter by putting sleeve etc.

Figure-1 shows the effect of raceway controlling on hearth wall temperature just below
the tap hole. Tuyere no. 9 or 10 was selected for blanking to increase the tap hole length
as well to decrease the turbulence of liquid just below the tap hole referring to hearth wall
temperature. A considerable decrease in temperature was observed during blank tuyere
condition.

390
Hearth wall temperature, 0C

340
180 0 , EL 9.5

290

240
120 0, EL 8.5

190

140
1 2 3 4 5 6 7 8 9 10 11

Fig. 1. Hearth wall temperature when No.9 or No.10 tuyere blanked.

Analysis of drainage rate:

For achieving high productivity and elongation of campaign life in blast furnace iron
making, it is essential to protect the peripheral iron flow formed by a free space in the
hearth in addition to maintaining the gas and liquid permeability of deadman. Therefore,
it is important to stabilize the tap hole length.

Fig: 2. Schematic illustration about coke consumption during tapping.

Seminar on Efficient Iron Making & Support Initiatives November 2009

During tapping, it is assumed that void fraction of deadman increases and pressure drop
decreases as coke particle dissolve into the liquid. Figure 2 shows the schematic
illustration about coke consumption during tapping. Gaps between coke particles are
regarded as fluid paths. It is reasonable to hypothesize that coke particle size diminishes
as to enlarge the fluid paths since the dissolving reaction occurs at contact surfaces
between coke particles and the liquid.
In Fig 3, Productivity, tap hole length and mud mass consumption rate are correlated.

3.00
Productivity, mt/m3/d

Productivity
2.60

2.20

1.80

1.40

1.00

2.1
Taphole length
Taphole length,m

2.0

1.9

1.8

1.7

26
Mud mass rate, kg/thm

22
Mud mass rate
18

14

10
Nov-08
Apr-08

May-08

Aug-08

Dec-08

Feb-09

Apr-09

May-09

Aug-09
Jun-08

Jul-08

Sep-08

Oct-08

Jan-09

Mar-09

Jun-09

Jul-09

Sep-09

Fig.3. Trend of productivity, tap hole length and mud mass consumption rate

Figure. 4 shows the relationship between the productivity and the tapping time, and it can
be observed that (R2=0.77) relation between productivity and tapping time holds good.

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 2.70

Productivity, mt/m3/d
2.40 y = 0.163x - 0.858
R2 = 0.770
2.10

1.80

1.50

1.20
13 14 15 16 17 18 19 20 21 22
Tapping time,hrs

Fig.4. Correlation between the productivity and tapping time.

Composition of metal and slag

At JSPL, BF#2, the chemical compositions of iron and slag to tapping time are observed
as shown in Fig. 5 and 6. Larger tapping time is achieved when carbon content in molten
iron increased or FeO in molten slag decreased.

As tapping progresses, particles diameter in coke layer becomes smaller and smaller due
to carbon consumption as a result of dissolution into hot metal and reduction of FeO in
slag and the tap hole diameter enlarges due to its wall wear [3].

22.0

20.5
Tapping time ,hr

y = 8.133x - 12.182
19.0
R2 = 0.675

17.5

16.0

14.5

13.0
3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4.0 4.1 4.2

C in Hot metal,%

Fig. 5.Relation between tapping time and C in hot metal

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 23.0
y = -19.451x + 31.248
21.5
R2 = 0.5614
Tapping time,hrs

20.0

18.5

17.0

15.5

14.0
0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85

FeO in Slag,%

Fig.6. Relation between tapping time and FeO in slag.

Influence of hearth bottom and hearth side wall temperatures.

To decrease the peripherial flow along the hearth wall and to maintain a floating dead
man an initiative was taken to provide Oxygen in the hearth in form of oxides.
A decrease in hearth wall temperature could be observed during this period when iron
oxides / sinter were charged in the centre of the furnace intermittently.

Metallic charge was introduced from 1.8.09 in centre of the furnace and continued till
9.8.09. A remarkable decrease in hearth side wall temperature was observed which
supported the permeable dead man phenomenon.

Hearth wall temperature, 0C at 180 0 and at EL 9.5

275

270
Temperature, 0C

265

260

255

250

245
8/1/09 8/2/09 8/3/09 8/4/09 8/5/09 8/6/09 8/7/09 8/8/09 8/9/09

Fig .7. The effect of Metallic charge on the hearth side wall temperature.

Fig 8. Shows trends of hearth bottom temperature and tapping time at BF -2.Two trends
indicate the relationship that the tapping time was relatively longer at the time period of
high hearth bottom temperature. These data are summarized into Fig 9.

Seminar on Efficient Iron Making & Support Initiatives November 2009

 67

temperature,0C
Hearth bottom
59
Hearth bottom temperature
51

43

35

25
Tapping time
23
Tapping time /hr

21

19

17

15
Dec-07

Feb-08

Apr-08

Aug-08

Dec-08

Feb-09

Apr-09

Aug-09
Jun-08

Oct-08

Jun-09

Oct-09
Fig . 8. Trend of hearth bottom temperature and tapping time at BF#2.

And it has been observed that an apparent relationship between BF hearth bottom
temperature and tapping time, which indicates higher hearth bottom temperature is a
result of high tapping time.

24
23 y = 0.240x + 8.558
22 R2 = 0.501
Tapping time. hr

21
20
19
18
17
16
45 47 49 51 53 55 57 59
Hearth bottom temperature, 0C

Fig. 9. Correlation between tapping time and hearth bottom temperature at BF#2.

Quality of the mud gun mass remains a key factor in building a proper tap hole concept.
In spite of all above mentioned qualities, a tap hole mass should be compatible towards an
individual furnace with its varying hearth profile.

Tap hole mass from various sources is being used in BF# 2. A list of chemical
composition and properties are in table No.2 .

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 Table 2.The typical quality data sheet of tap hole clay used in BF#II.

UOM Temp,0C A B C

Al2O3 % - 37.6 25.85 53.48

SiO2 % - 23.7 10.32 21.49
Chemical analysis C+ SiC % - 35.4 41.98 20.99
Si3N4 % - Nil - -
Others % -
Bulk Density g/cm3 RT 2.5 1.96 2.45
Apparent porosity % 800 37 - -
% 1000 - - 25.41
kg/cm2 900 - 90 -
Cold crushing strength kg/cm2 1000 90 - 50
kg/cm2 1200 - 86 -
kg/cm2 1400 60 - -
Volatile matter % 360 7.6 8.51 -
% 1000 - 10.81
L.O.I % 900 0.11 - -
Workability Index % 50 - - 35

It is needless to say that during varying operating parameter of BF, the consistency of tap
hole clay remains critical.

Key performance factors of a good tap hole clay:

Long tap hole length-This depends on the adhesion strength between old &
new clay.

Long Casting Duration & Uniform Casting Rate –It depend on the texture
development of the clay inside the blast furnace when the tap hole clay is
exposed at high temperature where corrosion, erosion are taking place. All
three play an important role in determining the properties of the tap hole clay.

Drilling operation-The ease of the drilling operation depends on the
expansion behavior of tap hole clay during sintering.

Role of tap hole mass:

o Allow Controlled Flow of Metal & Slag
o Ideally retain its shape & size throughout casting period
o Protect Hearth Lining in the Vicinity of Tap Hole
o Seal the metal flow when plugged in hole.
o Improve life of iron trough & hood by controlled flow of metals and slag.

Conclusion:

In the ongoing process of enhancing campaign life and increase productivity with low
fuel rate tap hole behaviour will remain critical due to its nature.
Though considerable improvements have been achieved through shift from hydrated tap
hole mass to resin bounded clay, improved drill machine and mud gun still the tap hole
remains concern of the BF operator for its criticality.

Seminar on Efficient Iron Making & Support Initiatives November 2009

In addition to correct cast house practice, proper hearth drainage and preventing hearth
wear, the tap hole concept is largely dependent on mud gun clay.
On going developments in mud gun mass like varying quality as per requirement ,
pushing of refractory along with mud gun mass are the new venture to cater high
productivity and higher campaign life, but stringent quality requirements of mud gun
mass will remain constant forever.

References:
1. Development of improved tap hole clay for blast furnace tap hole by Sruti Rekha
Dash.
2. Stabilization of tapping hole length by controlling blast furnace raceway depth by
Yoshiyuki Matsui, Rikizo Tadai, Kenji Ito, Tadasu Matsuo, Nobuyuki Nagai And
Takashi Imai (ISIJ International, Vol. 45 (2005), No. 10, Pp. 1439-1444).
3. Analysis of drainage rate variation of molten iron and slag from blast furnace
during tapping by Masakazu Iida, Kazuhiro Ogura And Tetsui Hakone (ISIJ
International, Vol. 48 (2008), No. 4, Pp. 412–419)
4. In furnace conditions as prerequisites for proper use and design of mud to control
blast furnace tap hole length by Nobuotsuchiyat Suyoshi Fukutake. Yutaka
Yamauch And Toshiyuki Matsumoto (ISIJ International, Vol. 38 (1998), No. 2,
Pp. 116-1 25)

Seminar on Efficient Iron Making & Support Initiatives November 2009