JFE技報 No.11 設備・メンテナンス特集号

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1 JFE No p. 1 8 Short-Term Revamping Technology for Large Blast Furnace FUJITA Masao JFE TOKUDA Keiichiro JFE KOJIMA Hirotaka JFE JFE JFE t t t Abstract: To revamp a blast furnace (BF) is required about every 15 years, and revamp duration by a conventional method is around 130 days. JFE Steel has developed a new revamping method, so called Large Block Ring Construction Method. By employing the method, the revamp duration was remarkably reduced to a half of a conventional one. A furnace body ( t) was segmented into blocks of 10 t to 20 t weight during dismantling and installation in conventional method. Blocks by the Large Block Ring Constitution Method weigh over t a piece. Consequently, the revamp duration of No. 6 BF at East Japan Works (Chiba) in 1998 was only 62 days, which was the world shortest record of revamp duration. The method was also successfully adopted to No. 5 BF at West Japan Works (Fukuyama) in 2005, and established a new world record of 58 days JFE ) m t t 3 4 Table 1 JFE 1998 Table 2 Fig. 1 5 JFE

2 Table 1 Comparison of conventional revamp and Large Block Ring Construction Method Revamp method Conventional revamp Large Block Ring Construction Method Height equal 30 FL building 110 m Total furnace weight: approximately t Large block ring weight: t Units weight: t Construction method Unit number and weight 30 m Carry t shell units into site and assemble at site units 1 unit: t Transport pre-assembled ring-blocks of t into site 3 4 units 1 unit: t Revamp duration 130 days 58 days Table 2 Revamp duration by large block ring method Chiba No. 6 BF Kurashiki No. 4 BF Kurashiki No. 2 BF Fukuyama No. 5 BF Revamp duration (day) Revamp time (year) Inner volume (m 3 ) Slag Residual iron Furnace Coke 200 (1) Dismantling of old hearth Revamp duration (day) Large Block Ring Construction Method Chiba No.6 BF (1998) 62 days Fukuyama No.5 BF (2005) days Safety ceiling Heath brick Old mantel piece Inner volume (m 3 ) Fig. 1 Relation between inner volume and duration of revamps (2) Dismantle of old furnace / Fig New mantle (3) Assembling of new mantle Fig. 2 Outline of conventional method 2 2

3 Rails 4.1 Fig (1) Dismantle of operating floor Lifting jacks m Moving Sliding platform platform 4 Fig. 4 1 Operating floor Transporting trucks Supporting columns Old mantel Mixed coke and slag Residual iron (2) Dismantle of hearth Transporting trucks (3) Dismantle of old furnace blocks Lifting Jacks Lifting Fig. 3 Outline of dismantling operation in large block ring method 4 3

4 Fig. 4 Mantle rest Top Shaft Bosh Hearth New furnace block (1) Pre-assembling of new furnace blocks Sliding platform Lifting jacks Sliding platform Rails Lifting jacks Lifting Moving platform Transporting trucks (2) Lifting up of new furnace block for transporting Supporting columns (3) Transporting of new furnace block Transporting trucks New furnace t (4) Assembling and lifting up of new furnace Outline of assembling operation in large block ring method t Fig. 5 Furnace shell Blast furnace Refractories Staves Hearth Bosh Shaft Top Lifting Connecting pipes (Outer side) Fig. 5 (Inner side) The section of furnace block Bricks laying after assembling Photo 1 Pre-assembling of new furnace blocks t Photo Lifting Photo 2 Furnace block t 4 points supporting in lifting 4

5 4 Photo t t t 3 3 m JBSD JFE Steel blast furnace structure design system 4) JBSD Fig t 5.3 1/10 1 Fig. 7 Structure of blast furnace Reinforced frame 2 6 mm 5.4 Furnace t Fig. 6 Model for framed structure analysis of blast furnace Subject for welding of outer side groove Impossible to fit backing plate at site Impossible to adjust linear misalignment without refractories cracks Furnace shell The site welding point (Outer side) Backing plate Refractories Staves Shell brace (Inner side) Fig. 7 The welding of one side groove 3 mm 5.1 5

6 Shell brace Bonding line at site maximum φ19 m 5.6 Assembling blocks in shop Linear misalignment in site bonding line 3 mm Fig mm t 1 2 Photo 3 Transporting mantle blocks 3 Preassembling blocks Bonding at site Linear misalignment in site bonding line 5.5 mm Fig. 8 Technology of precise bonding by welding between large block rings t t t 4 30 mm 10 mm Fig t m Residual iron block 550 t Lifting t Lifting jacks Columns 650 t Dispersing load by large slabs 40 t/m 2 / 23 t/m (day) 2 Spring back at unloading Ground settlement (mm) Preloading Unloading Actual loading Unloading Large slabs substituted for concrete foundation Ground settlement became less than 10 mm after preloading Photo 3 Hanging up large residual iron block Fig. 9 Technology of foundationless lifting and settlement trend at loading 6

7 Combination of rolling compacted ballast and steel plate /Relative settlement 30 mm φ1 500 mm 50 t Air Steel plate 25 mm Relative settlement 30 mm /Enhance applicable range of air caster with pin joint supporting frames Pin joint supporting frames Rolling compacted ballast Fig. 10 Technology of using foundationless air caster Chiba No.6 BF (1998) m 2 Adopted usual BF Kurashiki No.4 BF (2001) m 2 Operating floor Distance between blocks 15 m Movable lifting Operating floor Distance between blocks 3 m by using air caster Fixed lifting BF Dismantling yard Movable lifting Assembling yard of new furnace BF Dismantling yard Fixed lifting Assembling yard of new furnace Transporting truck length 30 m Fig. 11 Comparison of revamping area m m 15 m 4 3 m 0.35 MPa 35 t/m 2 a 25 mm b 30 mm Fig Fig

8 Conventional method Dismantling of hearth 20 (day) Dismantling of large residual iron blocks Structuring of new furnace Dismantling Installation Test run and of old furnace of staves drying of furnace Laying of bricks Dismantling and preassembling large blocks Preassembling of all staves Large Block Ring Method Chiba No.6 BF (1998) Fukuyama No.5 BF (2005) The shortest world record of revamp duration Fig. 12 Duration of revamps using conventional and new method Fig. 12 1/ m 3 1 Fujita, M.; Kojima, H.; Marushima, H.; Kawai, T. Iron and Steel Engineer , p Fujita, M.; Kojima, H.; Marushima, H.; Matsumoto, T.; Yokogawa, A. La Revue de Metallurgie , p vol. 32 no p vol. 15 no p JFE JFE

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