BLAST FURNACE STOVE
The Temperature that can be attained from stoves depends on
1.
2.
3.
4.
The Blast rate
Heat transfer rate depending on the shape and size of the checker.
Heat input rate which depends upon the burner capacity, the calorific value of the
gas.
The thermal efficiency which depends on the stack temperature and amount of
excess air.
Overall Heat transfer rate
During the On Gas period heat is transferred from combustion products (Gas + Air) to
the bricks. And during the On Blast, the same heat transferred from the bricks to the
air.
The amount of heat transferred per unit area of the surface depends on
1. The Air (from blower) velocity in the checker
2. The shape and size of the checker
If the checker hole are round then the heat transfer rate is more than the heat transfer
rate for square or rectangle.
3. The thermal conductivity and dimensions of the brick work to make the heat stored
inside the brick available at the surface.
4. The temperature difference between the air and brick surface.
Heat Storage Capacity of Stoves
The Heat Storage capacity of a stove is defined as the amount of heat the stove can
release to maintain a constant temperature in the blast. This depends on
Heat Input rate, heating time and thermal efficiency.
Mass of checkers and type of bricks.
Height and Diameter of the stoves
Heat transfer rate.
Temperature distribution in the checkers.
Dome and stack temperature.
Maximum Dome temperature & Maximum Flue (waste) Gas temperature.
The Quality of the bricks determine the maximum dome temperature of the
stove. It is important to isolate your stove atleast 50Deg.C before attaining
the maximum dome temperature is attained for better life of the dome
bricks. There should be an interlock between the maximum dome
temperature attained with the combustion air that is being supplied which
determines your flue (waste) gas temperature, which means if the dome of
1200 Deg.C is attained and flue gas temperature has not reached 350
deg.C, then the air to gas ratio should be adjusted such that the air inflow is
more than the gas flow and vice versa. If the higher flue gas temperature is
attained before dome reaches 1200 deg.C then the fuel (Air + Gas) has
been poorly utilized.
Cast Iron Grid supports of checker bricks have temperature limits. Usually the
stoves isolate after the flue gas has attained a temperature of 350Deg.C.
Cycles of Stoves
[Link] Gas or Heating of Stoves
2. Isolation
3. On Blast
Usually 3 stoves are designed for a single blast furnace, of which one stoves
will be on Blast and two stoves on Gas. It is the operators skill to adjust the
operation of these stoves to attain maximum dome temperature and Hot
Blast temperature consistently to the furnace. Usually a stove is on Blast
for 90 mins and On Gas for 120 Mins.
Types of Stoves
Internal Combustion chamber
External Combustion chamber
Kalugin Stoves.
How to increase the Stove temperature:
1. Increase the diameter of the stoves.
2. Adequate and optimum ration between gas/air.
3. Valves maintenance /schedule
4. Proper changeover timing
5. Clean Gas.
6. Clean Checker bricks.
Thermal Efficiency
The overall thermal efficiency depends upon the flue (waste) gas temperature,
the amount of excess air used and the radiation loss.
Banana Effect
In an internal combustion chamber, when the combustion chamber wall bends towards
the checker chamber, the effect is called the banana effect. Usually during this effect
short circuiting takes place, which means, the combustion flame directly goes towards
the chimney draft raising the flue gas temperature without raising the dome temperature.
A stainless steel plate of 2mm is given in between the checker and combustion chamber
wall to prevent this effect.
Skin Effect:
In actual practice, the higher volume the lower the temperature given by the stoves, in
skin effect, higher volume gives higher temperature.
Excess Air:
Whenever the flue (waste) gas contains O2 more than 1%, the excess air given into the
stove (On Gas period) is around 10%. This happens when the Air to Gas ratio is not
properly set.
Internal Combustion
External Combustion
Kalugin
Two chamber in the same
shell
Two different chamber for
combustion and checker
Single Chamber of checker
Tilting of the combustion
chamber
Separate combustion
chamber
Combustion chamber over
the checker chamber
Short circuiting of
combustion chamber with
checker chamber
Separate combustion
chamber
Combustion chamber over
the checker chamber
Reduction of checker
chamber due to circular
combustion chamber
Separate combustion
chamber
Combustion chamber over
the checker chamber
Lower Hot blast
Higher Hot Blast
Higher Hot Blast
Cost effective
Costlier
Cost effective
Less space required
More space required
Less space and less height
required
Interlocks in Stoves
There are a number of Interlocks in stoves and also the sequential operation of the
valves during On Gas, On Blast and Isolation.
Generally On Gas the Valves which open sequentially are Flue (Waste/chimney)
valve Air Valves- Gas Valves. And similarly during isolation from On Gas, the Gas
Valves close first followed by Air Valves - Flue (Waste/chimney) valve.
During On Blast The Cold Blast Valve opens first and then the hot Blast valves and
vice versa when stove isolates.
During Isolation the only valve which will be open is the Gas Bleeder.
There is a major interlock in stoves when the changeover of the stove during On
Blast take place. The second stove will have to come On Blast before the first stove
get isolated.
Determining Air to Gas ratio
Suppose the stove takes 10000 Nm3/hr.
then CO + 1/2 O2 = CO2
CO in gas = 25%
10000x 25/100 = 2500Nm3/hr
O2 in air is 20%
1/2 O2 = 1/2 2500Nm3/hr = 1250Nm3/hr is O2
20% of 100%, then 1% = 100/20= 5%, therefore 5 x 1250 = 6250Nm3/hr
therefore Air to gas = 6250/10000 = 0.625
..thank you
