Damage Mechanism of Copper Staves in a 3200 m3 Blast Furnace

Zuo, Haibin; Wang, Yajie; Wang, Xuebin

doi:10.3390/met8110943

Cited by 8 publications

(3 citation statements)

References 19 publications

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“…However, a large number of copper staves were damaged in the actual production process due to frequent shedding of the slag crust, and their service life did not reach the expected aim. [3,4] Therefore, understanding the slag crust properties (thickness, thermal conductivity, and melting characteristics, etc.) is essential for the stability and safety of copper stave blast furnace operations.…”

Section: Introductionmentioning

confidence: 99%

X‐ray Computed Tomography Characterization of Slag Crust and the Effect of Bubbles and Metallic Iron in Slag on Heat Transfer to Copper Stave

Wang

Liu

et al. 2023

steel research int.

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Understanding the heat transfer properties of the slag crust is critical to the safe operation of copper staves. The distribution of metallic iron and bubbles in the slag crust is detected by X‐ray computed tomography. The thermal conductivity of the slag crust is modified based on an effective thermal conductivity model and laser thermal conductivity measurements to predict the effect of metallic iron and bubbles on the heat transfer in the slag crust. The results show that the average volume fractions of metallic iron and air bubbles in the slag crust are 3% and 4.5%, respectively. The measured value is consistent with the trend of the effective thermal conductivity calculation model, and the calculation result of the Maxwell–Eucken effective thermal conductivity model is very accurate. Variations in the volume fraction of metallic iron in the slag crust have a greater effect on the thickness of the slag crust, while variations in the volume fraction of bubbles have a smaller effect on the thickness of the slag crust. It is recommended to keep it between 10 and 30 mm in blast furnace production to help improve the operational life of the copper stave.

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Section: Introductionmentioning

confidence: 99%

X‐ray Computed Tomography Characterization of Slag Crust and the Effect of Bubbles and Metallic Iron in Slag on Heat Transfer to Copper Stave

Wang

Liu

et al. 2023

steel research int.

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“…Only a few 2500 m 3 furnace copper cooling staves can last about 15 years. [10,11] The abrasion of the copper cooling stave by the furnace charge and slag is a significant cause of breakage. [12] Many studies demonstrate that high-intensity blast furnace smelting and fluctuating raw fuel quality will result in slag often dropping off the hot surface of the copper cooling stave.…”

Section: Introductionmentioning

confidence: 99%

Damage Mechanism of Copper Cooling Plate on Large Blast Furnace

Gao

Zhang

et al. 2023

steel research int.

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This paper investigates the application of cooling plate in a 4500m3 blast furnace in China. SEM‐EDS and an optical microscope were used to examine the affected area. The results demonstrate that using a cooling plate in a big blast furnace has a positive effect, notably in the belly and bosh areas, where the damage rate is less than 3%. While the cooling plates in the middle shaft are more severely damaged, with a damage rate of up to 55.40%. The majority of the copper cooling plate’s damage is centered in the water channel area, where there are furrows and numerous microcracks on the damaged surface, as well as a tiny quantity of metallurgical slag attached. Cracks form on both the inside and outside of the water channel, and the grains surrounding the cracks rise significantly, which is the primary cause of the cooling plate’s water leaking. The main factor of cooling plate damage in the early stage is wear, and the cracking caused by force in the later stage. The use of a copper cooling plate from the furnace bosh to the lower shaft is preferable to the use of a copper cooling stave.This article is protected by copyright. All rights reserved.

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“…The CO in the gas reduces the iron oxide in the iron ore into metallic iron while transferring heat to the burden. Through a series of complex physical and chemical interactions, the melting and separation of slag and iron are achieved [8][9][10]. The blast furnace is a large and efficient reactor that operates continuously, and the long campaign of modern large blast furnaces can reach 15-20 years.…”

Section: Introductionmentioning

confidence: 99%

Simulation and Validation of Thickness of Slag Crust on the Copper Stave in the High-Temperature Area of Blast Furnace

Liu,

Zhang,

Xue

et al. 2023

Metals

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The blast furnace is the dominant high-temperature reactor in the modern ironmaking industry. Iron oxide in iron ores can be converted to metallic iron through blast furnace smelting, and this high-temperature melting can be used to separate the molten iron from the gangue components. The formation and thickness of the hot-surface slag crust on the copper stave in the high-temperature area of the middle and lower parts of the blast furnace are crucial for the safe operation and long campaign of the blast furnace. To enhance the precision of determining the thickness of the slag crust in this specific region, samples were extracted from the hot surface of the copper cooler situated in the high-temperature area. This extraction was carried out during the maintenance procedure of the blast furnace stockline. Subsequently, the thermal conductivity and melting performance of the slag crust were measured. The slag crust thicknesses corresponding to the various temperature measurement sites of the stave were determined by developing a mathematical model for the heat transfer of the copper stave. The actual slag crust thickness measurement data were acquired while the blast furnace stockline was in operation, and the data were then utilized to corroborate the model’s predictions. A blast furnace with an effective volume of 3200 m3 was used to test the model. The average thickness of the hot-surface slag crust was computed for cases that occurred between 2020 and 2022. The data’s correlations with the blast furnace’s technical and economic indices during the same time period were examined. The findings indicated that the blast furnace’s operation indices improved with a thinner slag crust, but there was also a higher chance of damage to the copper stave’s internal cooling water pipes. Taking into account the technical and economic indices as well as a long campaign of the blast furnace, 150–200 mm is recommended as the appropriate average slag crust thickness on the surface of the copper stave in the high-temperature section.

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Damage Mechanism of Copper Staves in a 3200 m3 Blast Furnace

Cited by 8 publications

References 19 publications

X‐ray Computed Tomography Characterization of Slag Crust and the Effect of Bubbles and Metallic Iron in Slag on Heat Transfer to Copper Stave

X‐ray Computed Tomography Characterization of Slag Crust and the Effect of Bubbles and Metallic Iron in Slag on Heat Transfer to Copper Stave

Damage Mechanism of Copper Cooling Plate on Large Blast Furnace

Simulation and Validation of Thickness of Slag Crust on the Copper Stave in the High-Temperature Area of Blast Furnace

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