1. DESIGN FEATURES OF INDIAN BLAST FURNACES Authors:
K R Pal Chaudhuri, GM, MECON
S K Verma, Jt GM, MECON
S K Bhattacherjee, DGM, MECON
A Mondal, AGM, MECON
Presented by: S Sengupta, DGM, MECON

2. Abstract
We have attempted to highlight the design features of Indian BFs and bring out the “Technology Status” of existing as well as proposed BF installations both in the large & mini sectors to provide an insight to the operators as well as entrepreneurs. Some of major highlights of the paper includes:
Technological features of modern Indian BFs
Design features and pre – requisites of modern Ironmaking
Important BF design and operating parameters
Effect of various parameters on productivity & coke rate
International benchmarks
The Indian scenario

3. BF Technology Vs Alternative Ironmaking Processes
BF technology for Ironmaking will continue to dominate owing to various reasons:
Corex – Finex - Hismelt have only reached commercial stage
Investment in alternative processes has elevated business risks
Expansion plan under National Steel Policy necessitates adding large production modules through proven BF route
Upgradation and modification of existing BFs
Impovement in performance of BFs in terms of productivity, cost & environmental friendliness

4. Major Recent Greenfield & Brownfield Projects of India
TATA Steel G & H Blast Furnaces
Bhilai Steel Plant, BF No. 7
Bokaro Steel Plant, Blast Furnace No. 2
Rourkela Steel Plant, Blast Furnace No. 5 (commissioned)
ISP (IISCO) Steel Plant, Blast Furnace No. 5 (commissioned)
Bhilai Steel Plant, Blast Furnace No. 8 (under advanced stage of execution)
JSW Steel Limited, Blast Furnace No. 2, 3 & 4 (all commissioned)
Bhushan Power, Blast Furnace No. 1 & 2 (under execution)
Bhushan Steel Limited, Blast Furnace No. 1 & 2 (under commissioning)

5. Some Broad Details of Major Modern Indian BFs
Technology Supplier
Client
Major Technical Data
Remarks
Paul Wurth
Tata Steel, BF # H (commissioned )
Useful Volume: 3814 m3
Number of Tuyeres: 34
Hearth Diameter: 13.0 m
Production: 2.5 – 2.8 Mtpa
(7150 tpd for Bhushan & Tata BF # H has crossed 10,000 tpd)
Cooling System: Copper staves
SGP - PW INBA system
GCP - PW Annular Gap Scrubber
TRT MW (design)
Top charging - PW BLT system
Hot blast system - PW design
PCI system - PW design
Tata Steel, BF # I (under design & erection)
RINL, BF # 3
(under commissioning trials)
Bhushan Steel, BF # 2 (under construction)
POSCO e & c
ISP, New BF
(commissioned in Nov 2014)
Useful Volume: 4161 m3
Number of Tuyeres: 38
Hearth Diameter: 13.6 m
Production: 2.8 Mtpa (8000 tpd)
SGP - Rasman Screw type
GCP - Bischoff Annular Gap system
TRT - 14 MW (Mitsui & Nico)
Top charging- PW BLT system
Hot blast system - Danieli Corus
PCI system – CISRI/NMT/SPCL

6. Some Broad Details of Major Modern Indian BFs
Technology Supplier
Client
Major Technical Data
Remarks
Paul Wurth
Tata Steel, BF # G (Revamped in 2005)
Useful Volume: 2648 m3
Number of Tuyeres: 30
Hearth Diameter: 11.05
Production: 1.8 Mtpa (5150 tpd)
Cooling System : Copper staves
Double cast house
PW BLT system
PW GCP (Tangential cyclone + two stage venturi scrubber)
Danieli Corus BV
RSP, BF # 5
(commissioned in 2013)
Useful Volume: 4060 m3
Number of Tuyeres: 36
Hearth Diameter: 13.2 m
Production: 2.8 Mtpa (7984 tpd)
Cooling System: Copper plate coolers
SGP - DC Dewatering Wheel
GCP – DC Bischoff system
TRT - 14 MW (design)
Top charging - PW BLT system
Hot blast system - Danieli Corus
PCI system - Danieli Corus
Siemens VAI
JSW Steel (BF # 3 & 4)
(BF # 3 commissioned
BF # 4 under commissioning)
JSPL, Patratu (under construction)
Useful Volume: 4019 m3
Hearth Diameter: 12.6 m
Production: Presently ~ 8000 tpd
Cooling System: Copper staves
SGP - SVAI RASA system
GCP - SVAI system
Hot blast system - SVAI design
PCI system - SVAI design
BSP, BF # 8
(under advanced stage of execution)
Hearth Diameter: 13.4 m
Production: 2.8 Mtpa (8400 tpd)
SGP - PW INBA system
GCP - PW Annular Gap Scrubber
Top charging - PW BLT system
Hot blast system - PW design
PCI system - PW design

7. Some Broad Details of Major Modern Indian BFs
Technology Supplier
Client
Major Technical Data
Remarks
Paul Wurth
BPSL, BF #2
(under advanced stage of execution)
Useful Volume: 1701 m3
Number of Tuyeres: 24
Hearth Diameter: 8.7 m
Production: Mtpa (3800 tpd)
Cooling System: Copper staves
SGP - PW INBA system
GCP - PW Annular Gap Scrubber
TRT - 6 MW (design)
Top charging - PW BLT system
Hot blast system - PW design
PCI system - PW design
BSL, BF # 2
(commissioned – 2010)
Useful Volume: 2585 m3
Number of Tuyeres: 28
Hearth Diameter: 10.2 m
Production: tpd
SGP – Under Implementation
TRT – Not provided
Hot blast system – Existing modified
PCI system – Chinese design
Danieli Corus
BV & MECON
Limited
BSP, BF # 7
(commissioned – 2007)
Useful Volume: 2355 m3
Hearth Diameter: 9.75 m
Production: 1.5 Mtpa (4430 tpd)
SGP – Existing Russian system
Hot blast system – Existing Russian design
PCI system - DC design
Siemens VAI
RINL, BF # 1
(under commissioning)
Useful Volume: ~ 3800 m3
Number of Tuyeres: ~ 32
Hearth Diameter: ~ 12.5 m
Production: ~ 2.6 Mtpa (~ 7500 tpd)
GCP - SVAI Annular Gap Scrubber
TRT – Existing System retained
Hot blast system – Existing Russian design (proposal for up gradation)
PCI system – Being implemented

8. Some Broad Details of Major Modern Indian BFs
Technology Supplier
Client
Major Technical Data
Remarks
Danieli Corus BV &
MECON Limited
JSW, BF # 2
(commissioned)
Useful Volume: 1681 m3
Number of Tuyeres: 20
Hearth Diameter: 8.4 m
Production: Mtpa (3625 tpd)
Cooling System: Copper plate coolers
SGP - DC Dewatering Wheel
GCP – DC Bischoff system
TRT - Not envisaged
Top charging - TOTEM BRCU system for Jindal & PW BLT system for Bhushan
Hot blast system & PCI system – Danieli Corus
Apart from above medium to large size BF installations, entrepreneurs in MBF Sector are also increasingly adopting modern BF cooling system, Bell Less Top (BLT), high capacity cast house equipment, high temperature stoves including Top Fired Stoves, coal injection system & use of higher percentage of prepared burden are being increasingly preferred.

9. Modern Ironmaking Practices
Improved cooling system and refractory design alongwith optimum instruments
Proper burden distribution for proper central working, permeable deadman and reduced heat loss
High hot blast temperature and high top pressure BF operation
Nitrogen lean operation i.e., oxygen enrichment upto 4 – 6 %
Probes and instruments, particularly for controlling large BFs
Improvement in raw material qualities w.r.t. chemistry, consistency, granulometry & ratio of prepared burden
Provision of facilities for pollution control and environment friendly

10. Important BF Design/ Operating Parameters
Some important BF design/ operating parameters affecting plant campaign life and its productivity are:
High BF top pressure
High hot blast temperature
BF top charging equipment
BF refractory & cooling system
Stock house configuration & charging system
Raw material quality
Auxiliary fuel injection
Instrumentation & Automation
Energy monitoring and pollution control measures

11. Heat Load Fluctuation w.r.t Type of Operation & Burden Mix
Following table provides insight on peak heat load conditions alongwith typical heat load fluctuations (oC/ min)
Type of operation
Burden mix
Productivity on
Working vol.
Peak heat load
KW/m2
Heat load
Fluctuation (°C/min)
Low productivity
Iron Ore lump
< 1.5
10 – 40
6 – 10
Medium productivity
Lump + Sinter
1.5 – 2.2
25 – 95
15 – 50
50 – 190
35 – 70
High productivity
> 80% Sinter + < 20% Lump
2.2 – 2.7
70 – 250
50 – 105
> 30% Pellet + 50% Sinter + Balance Lump
100 – 190
In consideration to high productivity & long campaign life requirement, use of copper staves/ plates in contamination free closed loop soft water circuit alongwith compatible good quality refractory is desirable

12. Effect of Various Parameters on BF Productivity & Fuel Rate
Sl. No.
Item (Parameters)
Base
Value
Change
Productivity
Coke Rate 1.
Hot Blast Temperature
700 – 900 ° C C
+ 3 %
 3 %
900 – 1000 ° C
+ 2 %
 2.5 %
1000 – 1100 ° C
+ 1.5 %
 1.5 % 2.
Fe% in lump ore
62%
+ 1 %
1.0 % 3.
Fe% in Sinter/ Pellet 4.
Ash% in coke
15 %
+ 1%
 2 % 5.
Sinter% in Burden
70 %
+ 10 %
+ 2.5 %
2.5 % 6.
BF top pressure
1.0 atg
+ 0.1 % 7.
Burden Distribution: PW BLT/ TOTEM
Two Bell
Yes
- 2.0 % 8.
Si% in Hot Metal
0.5%
 (4 - 12) %
+ (5-15)% 9.
Raw Lime Stone/ Flux
+ 10 Kg
- 0.5 %
+ 3 Kg
10.
Slag rate
+ 10 kg
 0.5 %
+ 3 kg
11.
Fluctuation in Fe
1.0 % to 0.5 %
+ 2.0 %
12.
Addition of Metallic
10 Kg
+ 0.6 %
Source – Metallurgist Russian Handbook

13. Internationally Benchmarked BFs
Design/
Operating
Parameters
Unit
Danieli
Corus
BF # 7,
Ijmuiden,
Netherlands
POSCO
PWIT
BF # 2,
Thyssen
Germany
Baoshan
Steel
BF # 1 & 2
Inland
Corp.,
USA
NDK
BF # 3,
NSC,
Kimitsu,
Japan
BF # 2
Gwangyang
Steel Works
& BF # 3
Pohang Steel
Works
BF # 1 & 5
Useful volume (UV) m3
4450
4350
4020
4063
4403
Working
Volume (WV)
3790
3685
3445
4769
3525
3739
3545
Sinter in
burden % 76 74 85
85 – 86
100
Pellets in
8.2 12 10
NIL
Iron ore lump
In burden
% (max) 6
15.8 14
14 – 15
No. of tuyeres - 38 36 44
O2 enrichment 15
10-12
8-10
4-6 4

14. Internationally Benchmarked BFs
Design/
Operating
Parameters
Unit
Danieli
Corus
BF # 7,
Ijmuiden,
Netherland
POSCO
PWIT
BF # 2,
Thyssen
Germany
Baoshan
Steel
BF # 1 & 2
Inland
Corp.,
USA
NDK
BF # 3,
NSC,
Kimitsu,
Japan
BF # 2
Gwangyang
Steel Works
& BF # 3
PohangSteel
Works
BF # 1 & 5
Production
t/d
,632
9000
9230
11500
9025
10200
9250
Productivity
(on WV)
t/m3/d
2.2 – 2.8
2.37
2.68
2.41
2.17
2.5
Top pressure
bar
2.2
2.8
2.65
Hot blast
Temperature 0C
1250
1150 – 1200
1200
Coke rate
kg/thm
333
356
430
429
303
Coal dust
injection
200
177 – 189 75
27 (NGI)
203
Si in
Hot metal %
0.40
0.4
0.42
0.3
0.6

15. Internationally Benchmarked BFs
Design/
Operating
Parameters
Unit
Danieli
Corus
BF # 7,
Ijmuiden,
Netherlands
POSCO
PWIT
BF # 2,
Thyssen
Germany
Baoshan
Steel
BF # 1 & 2
Inland
Corp.,
USA
NDK
BF # 3,
NSC,
Kimitsu,
Japan
BF # 2
Gwangyang
Steel Works
& BF # 3
Pohang Steel
Works
BF # 1 & 5
Slag rate
kg/thm
267
285
295
290
Coke ash %
10.9 11
10.5
10.6
Charging system -
Bell Less
Note: The biggest Blast furnace of more then 5000m3 with productivity around 2.5/d/m3 have also been installed in number of countries like Japan, South Korea, Russia, Germany etc.

16. Indian Scenario
Indian Ironmaking has come of age with increased consciousness amongst operators to meet the requirements of competitive iron making at reduced cost with “Green Technologies”
The need of the hour is to adopt cutting edge innovative technologies to achieve:
Cost reduction
Improve specific consumption
Increase energy efficiency
Improve quality, yield & productivity
Increased automation & adopting ergonomic practices with a focus on environmental aspect

17. Present Trend in India
The present trend in India generally covers around the following major ideas:
Installation of bigger and large BFs to achieve economies of scale
Facilitating high productive operation at par with global benchmark
Increased stress on auxiliary fuel injection
Extensive use of energy saving measures and energy heat recovery systems
Increased awareness for quality and consistent raw materials
Compact installation and improved operating practices
Extensive automation and controls
Facilities for pollution control and environment friendly
Long campaign life of around 20 years
Use of top recovery turbine (TRT) for captive power generations.

18. Basic Design Features of Modern Indian BFs
Some of the basic design features embedded as an integral design concept for modern large BFs of India are:
Design suitable for long campaign life of 15 to 20 years
High intensification levels of production > 2.0 t/ m3 WV/ day
Closed circuit cooling for efficient and contamination free cooling
High top pressure operation (1.5 – 2.5 atg)
Straight line HBT of 1200 – C
PCI level > 120 kg/ thm
Installation of Top Recovery Turbine (TRT) – 14 MW for 4000 m3 BF
100 % slag granulation with dewatering facilities
Advanced charging practices and high levels of Instrumentation & automation
Maximum use of prepared burden, centre coke charging, two fraction sinter charging, base blending etc.
Extensive use of VVVF drives
Compulsory defuming and dedusting facilities
Advance technologies for environment friendly.

19. Mini Blast Furnace Sector – Indian Perspective
Even in Mini Blast Furnace (MBF) sector, plants are being built in 250 to 450 m3 size range with refractory & cooling system capable for longer campaign life of ~ 10 years & productivity levels of more than 2.5 t/ m3/ day on working volume basis.
Some of the MBFs in this segment, such as Adhunik (Rourkela), Jindal SAW (Bhuj), JSPL (Raigarh) & ECL (Kolkata) have touched 3.0 t/ m3/ d productivity levels quite consistently. Some of these MBFs have incorporated sinter charging (~ 50%) in burden & have injected ~70 kg/ thm PCI.
Top fired stoves for achieving 1200 °C hot blast temperatures are already implemented at Sunflag & Kirloskar with good results

22. Conclusions BF productivity largely depends on: BF top pressure
Hot blast temperature
Auxiliary fuel injection
Burden distribution and control
BF refractory and cooling system
Quality of input raw materials
BF stock house and charging system
Automation and Control
Increase of Oxygen content in blast
While configuring the BF plant, various design & operating parameters have to be selected in line with intensified operations similar to international benchmarks. However, due consideration to available raw materials & operating conditions have to be kept in mind.

23. REFERENCES
Metallurgists Russian Hand book. 1976
2. Modern Blast furnace – Mr. M Geerdes, H Toxopous, C Vardesvliet
3. International Seminar on “ Iron Making in Blast Furnaces” organized by “Steel Tech” in September 2010 at Kolkata

24. THANK YOU