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Velsen, Netherlands

Paramanathan B.K.,Aperam S.A | Engel E.,Danieli Corus BV
6th Int. Congress on the Science and Technology of Ironmaking 2012, ICSTI 2012 - Including Proceedings from the 42nd Ironmaking and Raw Materials Seminar, and the 13th Brazilian Symp. on Iron Ore | Year: 2012

The injection of reduction agents via the tuyeres is now common practice world-wide in blast furnace operation. The benefits of reduced coke consumption and increased production due to the removal of nitrogen from the blast with increasing oxygen enrichment have been recognized by the industry. In choosing an injection system, the user faces a choice of designs with fundamental differences, the most important of which is the type of flow control. Among the most common systems in the industry, some feature active flow control e.g. through the application of throttling valves, whereas flow control in the Danieli Corus system is based on physical principles such as uniform pressure drop across injection lines. For an optimized blast furnace process, production rates in front of the individual tuyeres should be balanced, and the production in front of a tuyere depends on the local coal to gas ratio. This article discusses how various designs perform in this respect. Source

Danieli Corus BV | Date: 2014-04-25

A method of conditioning particulate material and/or a gas is provided, comprising the steps of: feeding an amount of particulate material up to a filling level into in an inner volume of a silo having silo walls, a gas inlet and a gas outlet, and generating a gas flow of a gas from the gas inlet through the particulate material to the gas outlet which comprises applying suction to the inner volume of the silo through the gas outlet, wherein the gas outlet is located in a silo wall below the filling level and covered by the particulate material. A system is also provided.

Van Laar R.,Danieli Corus BV | Tsalapatis J.,Ironmaking
Iron and Steel Technology | Year: 2013

The fourth campaign of OneSteel Whyalla Blast Furnace started with advanced copper stave coolers in the bosh, belly and lower stack, high-grade silicon carbide and copper plate coolers in the lower bosh, and a high-grade mullite tuyere band. The design included a lower bosh steel shell expansion joint, but no matching refractory expansion joint. The bosh copper stave coolers suffered from erosion after three years of operational life, soon followed by bosh refractory lining and cooling plate failures and serious bosh shell and expansion joint hot spots. The major disruption to operational stability and high risk to safety were caused by bosh hot spots and cooling plate/expansion joint failures. A large number of regular bosh grouting stops were performed, while leaking copper stave coolers required several shutdowns for grouting and installation of internal sleeves. Trials to install copper cigar coolers also took place. The erosion of the bosh copper stave coolers is attributed to descending burden and lack of accretion protection of the bare copper hot face. The copper stave coolers have limited accretion anchoring functionality, and the bosh conical shape contributes to high-pressure loadings, which increase the erosion rates. There was no evidence of high-temperature softening or melting effects of the copper as all instrumentation data confirmed outstanding performance of the water cooling system. The lower bosh silicon carbide refractory cannot cope with high temperatures unless appropriate expansion provisions are utilized. Silicon carbide compressibility is very low, and this could cause cracking at temperatures around 200°C. The silicon carbide stress levels were high due to vertical constraints by the mullite tuyere band and bosh copper stave coolers. Also, the steel shell expansion joint is positioned at a critical elevation. Lower bosh silicon carbide refractory introduces a risk with regard to stress cracking, leading to loss of the refractory, and exposes the copper plate coolers and shell plate to high temperatures. The design caused high stresses and cracking of the copper plate coolers close to the shell. With the loss of refractory, the lower bosh steel shell expansion joint became exposed to high temperatures causing significant deformation and cracking. Eventually, the lower bosh expansion joint failures led to the decision toward a long-term campaign extension repair strategy and justification. A Hoogovens tuyere band, bosh and belly design was implemented, as many similar designs have been installed at comparable blast furnaces with a bosh expansion joint. It was decided to install new copper stave coolers in the lower stack and include an additional hot face lining of graphite and silicon carbide to provide a smooth transition of the belly Hoogovens lining to the middle stack cast-iron stave coolers. The post-mortem analysis confirmed the hypothesis regarding failures of the copper stave coolers and the lower bosh. This analysis also confirmed the decision to combine the Hoogovens tuyere band, bosh and belly together with the advanced lower stack copper stave coolers, as the observed lower stack copper stave cooler erosion was limited. Source

Van Laar R.,Danieli Corus BV | Engel E.,Danieli Corus BV
6th Int. Congress on the Science and Technology of Ironmaking 2012, ICSTI 2012 - Including Proceedings from the 42nd Ironmaking and Raw Materials Seminar, and the 13th Brazilian Symp. on Iron Ore | Year: 2012

Modern blast furnace ironmaking technology must comply with increasing environmental permitting and legislation and the blast furnace industry is simultaneously facing unreliable raw materials quality as well as high and volatile raw material prices due to high global demand. These challenges may be overcome by minimizing coke and energy consumption. This includes high pulverized coal injection, efficient gas cleaning and hot blast system technologies and a long campaign life blast furnace design. These technologies are discussed in the paper. Source

Schrama F.,Danieli Corus BV | Merkestein D.,Systems Navigator | Jansen M.,Systems Navigator | Vortrefflich W.,Danieli Linz Technology | Van Den Berg B.,Danieli Corus BV
Proceedings of the 6th International Congress on the Science and Technology of Steelmaking, ICS 2015 | Year: 2015

Danieli Corus and Systems Navigator have developed a Steel Plant Model (SPM) to solve bottlenecks and optimize logistics in both existing and new steel plants. The SPM is based on a three dimensional layout, where all movements, actions and interactions of all units, including cranes and ladles, are simulated. The SPM consists of a model and a Human Machine Interface (HMI). The SPM is object oriented and based on actual distances, speeds and processing times. The model includes deviations (e.g. standard or exponential deviations) of processing times as well as downtimes for maintenance and unexpected breakdowns into the simulations, making the results very realistic and accurate. When running the different scenarios that are available, several units, ladles and cranes can be added, modified or removed. This makes it very easy to determine for example where bottlenecks are, what the optimum amount of ladles is or what the return on investments such as the addition of another converter or caster will be. The SPM has been validated for several steel plants with widely ranging characteristics and layouts. It proves not only to be very accurate in predicting production figures like unit utilizations, intermediate waiting times and crane movements, but also to be able to visualize every movement inside the plant at any time. This makes the SPM a very powerful tool to find the weak spots in greenfield designs, when revamping plants and for plants that are in full operation. Given the flexibility of the SPM, any (new) steel plant can be simulated in quick order when a layout and the requested data are provided. This article discusses the basis of the model and presents its benefits. In addition, a case study that shows the capabilities of the SPM is highlighted. Source

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