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Reduction of Severe Erosion in The Basic Oxygen Furnace Vessel at Tata Steel, India
Reduction of Severe Erosion in The Basic Oxygen Furnace Vessel at Tata Steel, India
Reduction of Severe Erosion in the Basic Oxygen Furnace Vessel at Tata Steel, India
Mrityunjay Kumar Singh1, Ashutosh Kumar1, Rohit Agarwal1, Biswajit Ghosh1, Debashis Das1, Dirk van der Plas2, Hans
Pronk2, Sudhansu Pathak1
1
Tata Steel Limited,
Bistupur, Jamshedpur, Jharkhand, India, 831001
Phone:+ 91 7763807306
Email: mrityunjay.singh@tatasteel.com
2
Tata Steel Limited
Postbus 10.000, 1970 CA Ijmuiden, Netherlands
INTRODUCTION
In recent past, one of the BOF vessel of LD1 (vessel#2) has been reported to have severe erosion (see picture of the scan
image of the vessel as shown in Figure 1) during a campaign. An abnormal wear of bricks was found in bath pool region as
well as above bath volume. It was observed that in certain regions, erosion was alarming and bricks were completely eroded
as seen in Figure 1. This problem of premature failure of the vessel has led painstaking investigation of the cause behind this.
Numerous factors such as wear pattern, brick quality, slag splashing practice, hood pressure, exhaust gas CO during blow,
bath height, Argon and Nitrogen purging etc were analysed to get deep insight into the cause.
Figure 1: Evolution of vessel profile during a campaign: blue line shows the profile of bricks after a fixed life of operation.
Few key observations about the issue are outlined as follows:
• The previous campaign with vessel#2 was reported to be the best life with more than 6000 heats.
• No change in the brick quality from previous campaign to the severe erosion campaign was found.
• No abnormal change in the hot metal composition [P, S, Ti, Mn, Si etc] was reported.
• No abnormal mechanical failure in BOF area was registered.
Figure 2: Slag chemical analyses data for three campaigns: build up and top cone erosion, severe erosion, and best-ever
campaign. Left: slag Fe, middle: Slag MgO, right: Slag MnO.
The two operating vessels of the LD#1 (vessel#1 and #2) rely on scan images to set the lance height (HLance) during
operation. This is because both vessels have not been equipped with sub-lance system. In general, the frequency of scan is
after every 600 heats of operation. A typical lance profile and off-gas [CO2 and CO] for a heat is shown in Figure 3.
Figure 3: Lance profile and off-gas generation [CO and CO2] during processing a heat.
During processing (blowing) of a heat, a stable lance height (HLance) is maintained for most of the time. This HLance plays a
crucial role to dictate the flow regime and final Carbon (C) and Phosphorus (P) content of the liquid Steel. As campaign
proceeds, the vessel inner shape changes as shown in Figure 1 due to erosion and build-up. In principle, every heat can have
different bath height (HBath) due to erosion of bricks and build-up (solidified liquid metal) and hence requires height of lance
(HLance) to be maintained accordingly. The operator’s decision plays a crucial role in setting the lance height based on input
for bath height in level 2 system of HMI. There can be three situations first, the set lance height is greater than the ideal lance
height, second, the set lance height is less than the ideal lance height, and the third, the set lance height matches exactly with
ideal lance height. The above situations can be visualized as shown in Figure 4. The left picture shows a trend chart for bath
height set by operator and bath height based on scan images for a full campaign (in the range of 6000 heats). As evident, this
campaign in initial stages (<3000 heats) was executed where lance was closer to bath height, to say harder blow regime
(marked with green arrow). However, around 3500-4500 heats, the campaign was executed in a mode where lance was
farther to bath height, to say softer blow regime (marked with blue arrow).
Figure 5: Bath height actual vs bath height from scan, (a) Severe erosion campaign, (b) best-ever (highest life) campaign.
To unravel the above mystery, a detailed CFD analysis is performed for the BOF vessel regarding flow pattern and its impact
on health of the vessel.
Figure 10: Streamline patterns of O2 phase at three consecutive time intervals for two lance heights, LH=1.8 and 2.1 m.
Figure 11: Interaction of lance cavity with plume eye created by botton tyures (TBM), red circles: bottom plume eye, gray
empty space with red dots: cavity formed by lance.
The vicinity of plume eye to lance cavity in the case of LH=2.1 m brings instability in the plume and may lead to preferential
pushing of plume towards the vessel wall. This may lead to removal of weaker flows near the walls responsible for build-up.
Unstable plume leading to removal of weaker flows is key for faster mixing, however this will lead to faster erosion of the
vessel in the bottom part. This phenomenon can be depicted as shown in Figure 12. As stated earlier, the very dynamic plume
is required for vigorous mixing helping in improvement of dephosphorization and decarburization, however this can be
detrimental for health of the vessel. The bricks will erode faster in the bath area due to this vigorous churning of metal bath.
For LD#1 vessel #2, this vigorous churning was obvious from this analysis and had led for the bottom erosion.
Figure 12: Impact of lance height on stability of plume created from bottom tuyeres (TBM).
REFERENCES
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