Blast Furnace Design and Construction in Steel Plant

Since 2014, M HEAVY TECHNOLOGY has completed over 90 blast furnace design and construction projects.

The company has patent inventions that allow the following:

• To optimize the blast furnace process;
• To reduce consumption of conventional fuel;
• To minimize the impact on the environment.

For designing, construction, and modernization of the blast furnace facilities, the company provides comprehensive services using exclusively modern design methods such as BIM modeling and process CFD calculations.

Our engineering experts perform all project tasks for the blast furnace and auxiliary production facilities.

Technologies that reduce CO2 emissions

The issue of reducing CO₂ emissions in steel production is very critical. Changeover to direct iron reduction technologies does not eliminate the problem of CO₂ emissions either.
We offer developments that decrease the carbon footprint in blast furnace production.

A series of solutions are related to increasing the blast furnace operation efficiency and reducing energy consumption per ton of hot metal, ultimately leading to decreased coke consumption.

Other technologies are associated with recycling and reusing metallurgical gases (blast furnace, converter, coke gas) or replacing traditional reducing agents with hydrogen.

Modern cooling systems

In 2014, the company, for the first time, implemented its development of an “adaptive” cooling system, which makes it possible to adjust the cooling intensity depending on the thermal state of the furnace and thereby build up and constantly maintain the required scull layer on the refractory lining surface. This solution helps reduce heat losses by 4-5 times, decreasing coke consumption to 40 kg per ton of smelted hot metal.

Application of synthesis gas

Synthesis gas (syngas) is a mixture of hydrogen (H2) and carbon monoxide (CO), which replaces an essential part of solid carbonaceous fuel in the blast furnace process and herewith reduces carbon emissions associated with blast furnace production.

Application of coke gas as a replacement for natural gas injection through tuyeres

Due to its high calorific value of up to 18 MJ/Nm³, coke gas is a valuable energy source that replaces a part of coke in the blast furnace, thereby reducing CO₂ emissions.

Application of hydrogen as a replacement for natural gas injection or PCI (Pulverized Coal Injection) through tuyeres

The advantage of hydrogen lies in the fact that water vapor is emitted instead of CO₂. The maximum potential reduction in carbon dioxide emissions through hydrogen injection into the blast furnace can reach up to 20%.

Using blast furnace gas instead of nitrogen for process equipment cooling

M HEAVY TECHNOLOGY has developed a technological solution that replaces nitrogen, used for the coneless charging devices and other process equipment cooling, with blast furnace gas. After cooling the gearbox and blowing the chute and other equipment, the blast furnace gas comes back under the blast furnace mouth instead of being released into the atmosphere through the flair stack. The blast furnace gas recirculation takes place.

Technologies that improve efficiency

The blast furnace process is subject to constant modernization, and therefore, we propose a comprehensive range of modern technologies to enhance production efficiency:

“Adaptive” cooling system in combination with pre-lined copper, steel, and cast iron cooling staves

This technological solution significantly extends the blast furnace campaign, even under intensified smelting processes, increased pulverized coal injection (PCI), and loading 100% of pellets instead of using a sinter.

Furthermore, there is a significant reduction of:

• Blast furnace thermal losses; 
• Coke consumption; 
• Power use; 
• Water flow rate.

Modern stock houses with preparation of raw materials before charging the blast furnace

Screening out sinter and coke fines enhances the permeability of the burden, reduces batch carry-over with blast furnace gas, increases furnace productivity, and decreases coke consumption.

Chute-type coneless chargers

Installation of a chute-type coneless charging devices allows for a uniform burden distribution across the furnace top surface, prevents peripheral furnace operation, reduces the coke flow rate, and extends the furnace campaign.

Modernization of blast furnace dust catchers

The main idea of modernization of the blast furnace dust catchers by M HEAVY TECHNOLOGY is that two stages of purification are conditionally combined in the existing building of this unit:

• A stage of inertial dust settling in the central (paraxial) area of the dust catcher housing;
• A stage of centrifugal-vortex dust separation in the dust catcher housing’s peripheral (wall) zone.

The dust-collecting efficiency of the upgraded dust catcher increases by at least 1.5 times, reaching 90%. After wet cleaning stages, the slurry output is reduced by 3-4 times, amounting to approximately 15-20 t/day per blast furnace. Additionally, the zinc content in the slurry will proportionally increase and reach (under other equal conditions) 20-30%, allowing for its efficient utilization as a marketable product for zinc production.

Modernization of blast furnace hot blast stoves

M HEAVY TECHNOLOGY modernizes blast furnace hot blast stoves with minimal alteration to the existing configuration, precisely without sacrificing the existing casing, maintenance platforms, valves, and other components.

A ceramic burner is installed as the combustion device. This solution has the following advantages:

• The ceramic burner enhances mixing air and gas to ensure more complete combustion and higher heat-generating efficiency;
• The flame of the ceramic burner follows a strictly vertical trajectory and spreads parallel to the combustion chamber walls. It eliminates the possibility of local overheating, which used to occur due to uneven partition temperatures. The design of the ceramic burner prevents burn-throughs (short-circuiting) of the partition, significantly enhancing the durability of the hot blast stove and increasing thermal efficiency;
• The burner is silent in operation with minimal gas pressure losses. The flame is easily controlled, free of gas pulsations, and provides better heating than “pipe-in-pipe” burners.

To increase the heating surface area of the HBS checkerwork chamber, the company replaces the existing checkerwork blocks with a cylindrical channel diameter of 40 mm with new checkerwork blocks with conical channel diameters of 30 mm and 20 mm. These solutions enable an almost 2-fold increase in the heating surface area of the checkerwork.

Smart Solutions for Industry 4.0 and IIoT for Ironmaking

In partnership with TeraWatt Group, M HEAVY TECHNOLOGY offers various industrial automation solutions. We specialize in implementing Industry 4.0 and IIOT technologies for multiple processes in steel manufacturing and blast furnace operations. Our company boasts a comprehensive range of competencies that cover every aspect of ironmaking and metallurgical automation across the entire value chain.

Industrial Automation Solutions for Steel Manufacturing

We excel in providing services encompassing modern blast furnace design, supply, and commissioning of industrial automation systems. We offer a comprehensive range of offerings, encompassing instrumentation, APCS (Automation Process Control System), electrical equipment, power supply solutions, safety measures for personnel, and mechanisms safety. We rely on components from reputable brands such as Schneider Electric, Rockwell Automation, Phoenix Contact, Siemens, and Rittal and equipment from global manufacturers.

Our intelligent automation solutions for ironmaking offer numerous benefits to our clients, including:

• Cost reduction.
• Real-time operational insights.
• Traceable analytics and audits.
• Mitigation of potential human errors.
• Enhanced precision.

In addition to industrial process automation, our partner, TeraWatt Group, leverages intelligent solutions for Industry 4.0 and IIoT. Their specialization lies in crafting solutions for metallurgical processes, circulating water supply systems, and wastewater treatment facilities, all aimed at enhancing the efficiency of the steel manufacturing process.

One of our latest IoT solutions, “Production in the Pocket”, aims to provide users with quick, easily understandable, and reliable insights into production and equipment. Specifically, it offers:

• Aggregated data on equipment performance and production order fulfillment.
• Identification of deviations in product quality with pinpointed affected areas and associated orders (over the last shift, day, or week, etc.).
• Detection of equipment operational deviations over the previous shift, day, or week, etc., with quantified occurrences and affected areas.
• Summarized equipment performance indicators over a selected period.
• Comprehensive equipment status information, including current parameters, readings, and maintenance tasks data.

The “Production in the Pocket” solution tailored for blast furnace ironmaking offers comprehensive insights into baseline equipment status. It provides access to crucial information, including:

• Real-time comparison of current production volume with planned volume.
• Detailed and cumulative data on equipment operations and order fulfillment at specific stations.
• Data resilience: In case of a connection loss with the equipment, information is securely stored and synchronized with the database upon reconnection.
• Timestamp clarity: The solution indicates the time of the last synchronization, allowing users to assess the timeliness of the data.
• Archive mode functionality: Users can access historical parameters through graphs or reports for a selected period.
• Proactive notifications: The integrated Telegram bot sends alerts for specified critical equipment events, ensuring timely information dissemination to users.

The integration of green technologies with Industry 4.0 is crucial, given the impact of steel manufacturing on the environment. These technologies represent a significant source of future solutions, harmonizing the triple-bottom-line principles and economic, environmental, and social aspects within the production context. The IoT platforms and functionalities implemented by the Terawatt Group within steel plants cover a broad spectrum of solutions, including: 

• Data retrieval from external systems and generation of planned order lists.
• Tracking order execution for each equipment unit.
• Recording production history, manufacturing, and operational performance indicators of drawing machines.
• Monitoring product quality (with relevant sensors or ordered sensors).
• Recording defects and analyzing equipment downtime (if appropriate sensors are present or ordered).
• Tracking overall equipment and workshop productivity.
• Managing and analyzing the causes of equipment downtime, technological deviations, and performance metrics.
• Providing an operator interface for entering reasons for equipment downtime.

Here are the key benefits of utilizing the Terawatt Group’s solution in blast furnace ironmaking:

• Advanced analytics for pinpointing system weaknesses by analyzing device failures.
• Development of predictive models to estimate equipment failure probabilities.
• Creation of models to forecast energy consumption under specific conditions.
• Implementation of autonomous models for detecting anomalies in an object’s technological parameters and modes.
• Seamless transmission of operational data to the maintenance management system, including operating hours and instances exceeding specified parameter thresholds.

We specialize in deploying automation systems that ensure data serves its owners effectively. Our partner, the TeraWatt Group, brings extensive expertise in information technologies, the Industrial Internet of Things (IIoT), and augmented reality and in implementing electrical systems and automation solutions. Consequently, we possess the know-how to collect precise and valuable data about the production process.

Our manufacturing engineering consulting services help you optimize the processes, enhance efficiency and save cost.

In collaboration with the TeraWatt Group, M HEAVY TECHNOLOGY has successfully executed numerous projects within the steel manufacturing sector. These projects encompass blast furnaces for ironmaking, rolling mills, agglomeration machines, boiler facilities, pump stations, gas purification installations, and more. The TeraWatt Group has a track record of implementing IIoT and MES (Manufacturing Execution System) projects since 2008. Our global collaboration with clients, including those within the EU, has granted us insights into diverse production processes and their unique characteristics. With our proprietary technological processes and a team of skilled engineers, TeraWatt provides tailored solutions for blast furnace ironmaking grounded in the intrinsic value of process data.

Are You Curious If We Have Reliable Solutions For Your Type of Steel Plant? Check this Together With Our Professionals.

Contact us

M HEAVY TECHNOLOGY provides the following services on the design, construction, and modernization of modern blast furnace production facilities:

Central unit

Calculation of profile characteristics depending on the specific situation: PCI or natural gas, quality of feedstock (including operation with a large number of pellets, up to 100%), performance requirements, type of loading device, etc.

During reconstruction of existing blast furnaces, the furnace profile is optimized by raising the “dead layer” and the metal receiver. The number of air tuyeres and the quantity of cast iron tapholes increases.

Engineering and supply of all cooling staves (copper, cast iron, and steel), including pre-lined ones. Precise selection of material and the cooling plate design for a specific zone of the blast furnace, taking into account characteristics of the loaded material and the physical and chemical processes taking place in that zone.

Engineering and supply of the blast furnace lining, from the metal receiver and up to the top. Lining calculation is done zone-wise based on the processes occurring in those zones, using microporous carbon blocks, a ceramic “cup” in the bosh and hearth, and silicon carbide bricks in the bosh and furnace shaft.

Design engineering of self-supporting blast furnace shells and support systems, including performing all necessary calculations.

Design engineering of automation and control systems for process parameters in blast furnaces, methods for detection of lining erosion, diagnosing thermal conditions inside the blast furnace, charging profile, etc.

Casthouse

Design engineering of cast houses with new developments for installing modern hot metal and slag runners, new hydraulic cast house machinery, efficient dedusting systems design, and granulation plants.

M HEAVY TECHNOLOGY developments:

• The runners’ design makes using modern, high-resistant refractory mixtures possible;
• Casthouse floors are horizontal; 
• Main, transport, and tilting troughs are equipped with covers. The top of the transport trough covers is at the same level as the top of the working platform, making it possible to use floor-level mechanization tools for cast house operations;
• While designing, dust emissions and the entire dedusting system are calculated through CFD modeling;
• We use hydraulic machines for taphole opening and closing and cover manipulators of our strategic partner DHM GROUP.

Blast furnace charging system

Design engineering of the charge-conveying system allows for preparation, dosing, and making charge mix for blast-furnace smelting with screening fines and exhausting dust-loaded air from junction houses. 

After preparation, raw materials are fed to the top utilizing a skip hoist or conveyor. DHM GROUP coneless top chargers are installed in our projects for burden charging directly into the blast furnace.

Hot blast stove block

To increase the hot blast temperature and reduce harmful emissions into the atmosphere, our company proposes the installation of modern high-temperature hot blast stoves of shaftless design, which provide:

• Blast temperature increases up to 1300°С;
• Efficient gas combustion and low carbon monoxide (CO) content in the flue gases;
• The drawbacks of hot blast stoves with built-in combustion chambers are eliminated (direct gas flows between the combustion chamber and the checkerwork, deformation, and collapse of the combustion chamber, pulsating combustion, uneven distribution of combustion products along the checkerwork, etc.);
• High resistance of the hot blast stove dome and checkerwork.

Using the heat of the exhaust flue gases is suggested to raise the blast temperature while reconstructing existing HBSs with integrated combustion chambers. For this purpose, the hot blast stoves are equipped with heating fuel gas and combustion air systems.

Read also our flue gas cleaning guide.

Besides, our company has experience modernizing existing blast furnace HBSs with an external combustion chamber, making minimal alterations to the existing configuration (the shell, maintenance platforms, equipment, etc.). In these projects, we use a ceramic burner that enhances air and gas mixing, providing more efficient combustion and higher calorific value. To increase the heating surface area of the chamber checkerwork, our company replaces existing checkerwork blocks having a cylindrical channel diameter of 40 mm with new checkerwork blocks with conical channel diameters of 30 mm and 20 mm. These solutions make it possible to increase the heating surface area of the checkerwork almost twice.

Cooling system

M HEAVY TECHNOLOGY has extensive experience in the implementation of all types of blast furnace cooling systems:

• Open-loop cooling with process water, evaporative cooling system; 
• Closed loop cooling system using “hot” and “cold” chemically treated or softened water; 
• “Adaptive” systems.

Our experts have a client-oriented approach to selecting and implementing the systems to match your specific situation, considering aspects of reliability, CAPEX, and OPEX.

M HEAVY TECHNOLOGY has a patent for creating “adaptive” cooling systems. These systems have been implemented and successfully operated for many years at many enterprises, including Blast Furnaces 2, 3, 4, and 5 at “Zaporizhstal” PJSC, Blast Furnace No. 4 at “Ilyich Iron and Steel Works” PJSC, Blast Furnaces No. 3 and No. 4 at “Azovstal” PJSC.

The main feature of the “adaptive” system is automatic control of the cooling intensity of the blast furnace components depending on changes in the thermal state of the metallurgical unit. Along with pre-lined (silicon carbide bricks) copper cooling staves, this system makes it possible to increase and, most importantly, continuously maintain the required scull layer on the refractory lining surface. It effectively prevents both cooling staves and lining from damage, significantly reduces heat losses within the system, and consequently minimizes coke or “conventional” fuel consumption.

Complex approach

Our company covers all stages of work related to establishing new or reconstructing existing blast furnace production facilities:

• Scientific research;
• Analytic investigation of the existing production;
• Consulting services.

The company performs all stages of engineering: 

• Front-end engineering design;
• Basic engineering; 
• Detailed engineering.

The company provides services for the development, manufacture, and supply of equipment:

• Cooling staves; 
• Lining; 
• Cast house machinery; 
• Pumping equipment; 
• Heat exchangers; 
• Shutoff and control valves, coneless top chargers; 
• And other associated equipment.

Our experts perform commissioning works, installation supervision, and bringing up the facility to guarantee and design performance.

The company competencies apply to the entire complex of the blast furnace shop, starting from the central unit to auxiliary production.

Modern design methods

We use only modern techniques in our work:

• BIM design engineering;
• CFD modeling;
• Consulting program based on artificial intelligence.

Use of author’s unique developments

• “Adaptive” cooling systems;
• Different types of cooling staves in one project;
• Reconstruction of existing blast-furnace dust catchers at minimal costs and achievement of maximum indicators for blast-furnace gas purification;
• Modern cast houses with state-of-the-art dedusting systems;
• Solutions on enhancing air tuyeres lifetime, etc.

Are You Still Trying to Determine if We Can Cover All the Local and International Requirements for a Modern Steel Plant? Drop a Line to Our Professionals and Get All the Answers to Your Questions.

Schedule a call

Oleksandr Vasyliev

Chief designer of the blast furnace department

Tetiana Bondarieva

Chief of the blast furnace department

Kateryna Kushnarenko

Group leader of the BF department

In the early 2010s, the “METIVEST” company began to widely implement the PCI technology (pulverized coal injection) at blast furnaces and simultaneously intensify blast furnace smelting processes, increasing the amount of injected PC fuel to 180-200 kg/ t of HM. 

Because the design of blast furnaces, cooling staves, and cooling systems were not adapted to these solutions, problems with the durability of such staves arose at all blast furnaces, and namely, the bodies of cast iron cooling staves were completely damaged. 

The cooling system did not function properly in the areas where the staves were damaged, resulting in the blast furnace shell overheating. Reddening of the blast-furnace armor appeared; subsequently, it caused significant deformation of the furnace shell.

That is why finding a solution that would quickly solve this problem with relatively small capital investments was vital. M HEAVY TECHNOLOGY proposed such a solution. In a few years, some “METIVEST” blast furnaces at once received an adaptive cooling system developed by the company (Blast Furnaces 2, 3, 4, and 5 of “MK Zaporizhstal” PJSC, Blast Furnace No. 4 “Ilyich Iron and Steel Works” PJSC, Blast furnaces No. 3 and No. 4 at “Azovstal” PJSC.)

Basic attributes of an “adaptive” cooling system:

1. Pumping units with frequency control of the E-motor rotation speed. 
2. Copper or steel cooling staves, pre-lined with silicon carbide bricks, fitted out with thermocouples for measuring the temperature of the cooling stave body.
3. An automation system would enable control of the rotation speed of pump unit motors and thereby change the flow rate of the cooling water fed to the cooling staves depending on the stave body temperature.
4. A closed-loop cooling system that uses chemically treated water. It can be a traditional scheme with “cold” chemically treated water, a “hot” chemically treated water scheme, or even evaporative cooling.

Main advantages of the “adaptive” cooling system:

1. The issue of cooling staves burnout and, consequently, blast furnace shutdown is entirely resolved. By building up and maintaining a constant necessary scull layer on the refractory lining surface, we not only prevent cooling plate failure but also preserve the protective lining to the maximum extent.
   Over a decade of operating our systems, none of our copper cooling staves has been damaged.
2. Reduction of power consumption to 1000 kW/h due to frequency control.
3. Reduction of heat losses with the cooling system, a maximum of five times, and, as a result, saving coke flow rate to 50 kg per 1t of hot metal. 
4. Reduction of cooling water consumption, up to creating a completely closed system that does not require water makeup during operation.

Specialists of M HEAVY TECHNOLOGY have extensive experience both in the development of blast furnace construction strategies and in solving specific problems of particular production units, up to creating a digital twin of the furnace and calculating the necessary parameters, such as: 

• Energy and raw material balances; 
• Thermal state of the device; 
• Calculation of ongoing redox reactions; 
• CAPEX/OPEX calculations. 

We can also provide our recommendations for the following:

• Selection of blast furnace equipment;
• Replacement or upgrading of weak units and dysfunctional units and aggregates;
• Increasing durability and saving energy and resources of the enterprise;
• Solutions to environmental issues; 
• Excess blast-furnace gas utilization, etc.