China’s Largest Blast Furnace Back in Action After Danieli Corus Modernization
Jiangsu Shagang Group’s 5800-cubic-meter blast furnace #4, located at its Zhangjiagang facility in the Jiangsu province, has been brought back into operation following a comprehensive upgrade performed by Danieli Corus. This modernization project, which focused on extending furnace campaign durations, marks a major achievement in blast furnace technology. It represents a critical move towards ensuring the furnace’s long-term efficiency and environmental sustainability.
The project entailed the replacement of key components, specifically the bosh, belly, and lower stack zones, with a cutting-edge Danieli Corus high-conductivity lining design. This new design features a dense pattern of copper plate coolers combined with graphite refractory, a marked improvement over the older stave cooling system. The upgrade aims to prevent heat losses, ensuring greater control over the production process while also extending the furnace's operational life.
Key Features of the Modernization
The modernization project aimed to tackle several critical issues in blast furnace operations. Notably, it was designed to enhance the cooling system's capacity, allowing the furnace to endure longer campaigns without overheating or risking structural integrity. Here are some key elements of the upgrade:
• Copper Plate Coolers and Graphite Refractory: The innovative lining system now implemented provides significantly improved heat conductivity, reducing the potential for excessive heat buildup and ensuring more efficient cooling.
• Heat-Loss Monitoring System: A Level 2 heat-loss monitoring system was installed, which provides real-time data on heat losses across eight sections and at three distinct levels. This improvement ensures better process control and enhances operational safety.
• Furnace Integrity: The new system has demonstrated its capacity to handle high heat loads effectively, allowing the furnace to operate safely even under intense conditions. Average shell temperatures have remained below 60°C, well within the safe operational range.
Impressive Results and Performance Metrics
The results of the upgrade have been remarkable, showcasing the furnace's enhanced efficiency and longevity:
• Furnace Restart Time: The furnace was successfully restarted just over four months after the blow-down, a highly efficient timeline given the scale and scope of the modernization work.
• Coke Consumption Reduction: The upgraded furnace has seen a significant reduction in coke consumption, achieving a coke rate of 326 kg per metric ton of hot metal. This represents a 6% reduction compared to previous levels, leading to both cost savings and a reduction in environmental impact.
These outcomes demonstrate the success of the modernization in improving both operational performance and sustainability. By reducing coke consumption, the furnace is not only operating more efficiently but also contributing to the reduction of greenhouse gas emissions—a key goal in the global shift towards greener industrial practices.
Key Takeaways:
• Jiangsu Shagang’s 5800 m³ blast furnace #4 has been modernized by Danieli Corus, enhancing its operational efficiency.
• Key upgrades included high-conductivity linings with copper plate coolers and graphite refractory for improved heat management.
• A Level 2 heat-loss monitoring system was installed to ensure optimal process control and prevent heat loss.
• The furnace was restarted just over four months after the blow-down, a swift achievement given the scale of the modernization.
• Coke consumption was reduced by 6%, reaching a new coke rate of 326 kg/tHM.
• The average shell temperature of the furnace has remained safely below 60°C, indicating enhanced furnace integrity.
• These improvements extend the furnace’s operational lifespan and contribute to environmental sustainability through reduced energy consumption and emissions.
Danieli Corus’s role in this modernization highlights its commitment to innovative technologies and long-term solutions in the steel industry, particularly in enhancing the performance and sustainability of large-scale industrial operations.
