Effects of post combustion temperature on the wear of the supersonic nozzles in BOF lance tip
2019
Author:
Resume:
This paper studies the influence of post-combustion on supersonic lance tip nozzles wear for an 80t converter, using CFD (Computational Fluid Dynamics) simulations. These analyses were based on flow profile determination of supersonic jet at minimum and maximum operation flow rates, where it could be verified post-combustion inside the nozzles at lowest flow rates. Additionally, thermal input generated by post-combustion was exported as heat flow in order to serve as a boundary condition in CFD thermal exchange simulations, also considering nozzle internal cooling. With these simulations, it was shown that copper actually reaches its melting point, at which the lowest operating flow allows post-combustion inside the nozzle. The temperature distribution profiles and the high temperatures found were also relevant for a considerable grain growth found in the wear region, according to metallographic analyses. It was thus concluded that wear occurs due to the progressive melting of copper after continuous heats with low oxygen flow rates; post-combustion inside the nozzles is the root cause for this failure. Lance tip Supersonic nozzles Wear CFD BOF converter
Resume:
This paper studies the influence of post-combustion on supersonic lance tip nozzles wear for an 80t converter, using CFD (Computational Fluid Dynamics) simulations. These analyses were based on flow profile determination of supersonic jet at minimum and maximum operation flow rates, where it could be verified post-combustion inside the nozzles at lowest flow rates. Additionally, thermal input generated by post-combustion was exported as heat flow in order to serve as a boundary condition in CFD thermal exchange simulations, also considering nozzle internal cooling. With these simulations, it was shown that copper actually reaches its melting point, at which the lowest operating flow allows post-combustion inside the nozzle. The temperature distribution profiles and the high temperatures found were also relevant for a considerable grain growth found in the wear region, according to metallographic analyses. It was thus concluded that wear occurs due to the progressive melting of copper after continuous heats with low oxygen flow rates; post-combustion inside the nozzles is the root cause for this failure. Lance tip Supersonic nozzles Wear CFD BOF converter
Practical Approach of Penetration Index Equations for Use in BOF Blowing Pattern Design
2018
Author:
Breno Totti Maia 1, Roberto Parreiras Tavares 2, Shank Balajee 3, Jürgen Cappel 4.
Resume:
Several equations are developed over the years to calculate the penetration depth L of the Oxygen jet generated by the blowing lance for BOF/LD converters and similar processes. The penetration depth L for a given lance tip is primarily impacted by the lance height (gap), the oxygen flow rate and the resulting Oxygen jet momentum. Con¬sidering a dimensionless parameter L/Lo, where Lo is the liquid steel bath height, this paper will critically review both the theoretical and practical aspects of these depth of penetration equations, and recommend the most feasible equation(s) to determine the lance gap to use during the oxygen blow. Further the effects of the penetration depth, like: total surface of the penetration cavity, which is the reaction surface for direct reaction of Oxygen with the metal bath, and droplet generation and size, which is the reaction surface for reaction of Fe droplets with slag FeO will be discussed. BOF/LD Converter, penetration depth L, liquid steel bath height L0, lance height, oxygen flow rate, lance tip, Oxygen nozzles
Breno Totti Maia 1, Roberto Parreiras Tavares 2, Shank Balajee 3, Jürgen Cappel 4.
Resume:
Several equations are developed over the years to calculate the penetration depth L of the Oxygen jet generated by the blowing lance for BOF/LD converters and similar processes. The penetration depth L for a given lance tip is primarily impacted by the lance height (gap), the oxygen flow rate and the resulting Oxygen jet momentum. Con¬sidering a dimensionless parameter L/Lo, where Lo is the liquid steel bath height, this paper will critically review both the theoretical and practical aspects of these depth of penetration equations, and recommend the most feasible equation(s) to determine the lance gap to use during the oxygen blow. Further the effects of the penetration depth, like: total surface of the penetration cavity, which is the reaction surface for direct reaction of Oxygen with the metal bath, and droplet generation and size, which is the reaction surface for reaction of Fe droplets with slag FeO will be discussed. BOF/LD Converter, penetration depth L, liquid steel bath height L0, lance height, oxygen flow rate, lance tip, Oxygen nozzles
JSW IMPROVEMENTS IN BOF LANCE BY SLAGLESS CLEAN UP® TECHNOLOGY
2018
Author:
Breno Totti Maia1, Bruno Orlando de Almeida Santos (in memoria)1, Fabrício Silveira Garajau1, Marcelo de Souza Lima Guerra1, Wellington Ferreira Andrade1, Raju PSJKK1, Abhijit Sarkar2, Veeresh Bellatti2, Prabhanjan Y2, Vishwanath SC2, Sekhar VR2, Ganapathi Prasad2, Murthy VSN2, Dinesh Kumar C2, Sadanand Naik2, Navin N Desai 2.
Resume:
"The BOF (Basic Oxygen Furnace) is most important furnace in steel production, with 53% of the total amount of steel produced through BOF route around the world. JSW Steel Limited, India produces 12 million tons steel per year, composed of 03 steel shops facilities in one location. Steel Melting Shop One (SMS-I) has 03 BOF converters with 135 tons capacity each. The SMS-II has 04 BOF converters with 180 tons capacity each and SMS-III with 1x160 ton EAF Furnace. India’s largest integrated complex intend in the near future to build SMS-IV and will reach 16 million tons of steel per year. Continual improvement in Technology and optimization of process has made JSW grow from 0.8 million tons to 12.0 million tons in very short span of 19 years. The other side, common problems during operations of BOF happens like: Jam’s formation of blowing lance and converters mouth with dirty skirt. Efforts are made every day to avoid and reduce these effects and increase productivity and reduce costs. This present paper, the focus was enhanced blowing lance operation, reduction of lance jam and converters mouths jam of BOF shops. A new concept of lance tips was introduced for the same to improve more stable conditions during long life lance tips called “Slagless Clean Up cartridge”. The target of this work is shown new conditions to reach like: increase cartridges life, reduce jams around lance and mouth contribute for stable operations." BOF; Blow; Cartridge; Tip life; Jam.
Breno Totti Maia1, Bruno Orlando de Almeida Santos (in memoria)1, Fabrício Silveira Garajau1, Marcelo de Souza Lima Guerra1, Wellington Ferreira Andrade1, Raju PSJKK1, Abhijit Sarkar2, Veeresh Bellatti2, Prabhanjan Y2, Vishwanath SC2, Sekhar VR2, Ganapathi Prasad2, Murthy VSN2, Dinesh Kumar C2, Sadanand Naik2, Navin N Desai 2.
Resume:
"The BOF (Basic Oxygen Furnace) is most important furnace in steel production, with 53% of the total amount of steel produced through BOF route around the world. JSW Steel Limited, India produces 12 million tons steel per year, composed of 03 steel shops facilities in one location. Steel Melting Shop One (SMS-I) has 03 BOF converters with 135 tons capacity each. The SMS-II has 04 BOF converters with 180 tons capacity each and SMS-III with 1x160 ton EAF Furnace. India’s largest integrated complex intend in the near future to build SMS-IV and will reach 16 million tons of steel per year. Continual improvement in Technology and optimization of process has made JSW grow from 0.8 million tons to 12.0 million tons in very short span of 19 years. The other side, common problems during operations of BOF happens like: Jam’s formation of blowing lance and converters mouth with dirty skirt. Efforts are made every day to avoid and reduce these effects and increase productivity and reduce costs. This present paper, the focus was enhanced blowing lance operation, reduction of lance jam and converters mouths jam of BOF shops. A new concept of lance tips was introduced for the same to improve more stable conditions during long life lance tips called “Slagless Clean Up cartridge”. The target of this work is shown new conditions to reach like: increase cartridges life, reduce jams around lance and mouth contribute for stable operations." BOF; Blow; Cartridge; Tip life; Jam.
PERFORMANCE IMPROVEMENTS IN BOF AT ARCELOR MITTAL MONLEVADE BY TECHNOLOGY SLAGLESS® LANCE
2017
Author:
Cesar Sato[1], Dayvison Carlos Oliveira1, José geraldo Torres1, Breno Totti Maia{2}, Fabrício Silveira Garajau2, Marcelo de Souza Lima Guerra2, Wellington Morais de Andrade2, Willian dos Reis Lima2.
Resume:
In these hard days for Brazil steel market, all steel shops want to achieve the same goal, work with: productivity, low costs and high performance. In this scenario the Slagless® technology (which is applied into BOF converter) was important to reach these targets. After use has been reduced the number of times of tip exchange in more than 04 times. Was reduced too, the time to remove lance skulls. Lance keeps clean during all his life with record number of the life 1255 .Blow keep stable due strong measure control at the nozzles and more improvements are planning. BOF, cartridge, process control, post combustion tip life, lance skull, safety.
Cesar Sato[1], Dayvison Carlos Oliveira1, José geraldo Torres1, Breno Totti Maia{2}, Fabrício Silveira Garajau2, Marcelo de Souza Lima Guerra2, Wellington Morais de Andrade2, Willian dos Reis Lima2.
Resume:
In these hard days for Brazil steel market, all steel shops want to achieve the same goal, work with: productivity, low costs and high performance. In this scenario the Slagless® technology (which is applied into BOF converter) was important to reach these targets. After use has been reduced the number of times of tip exchange in more than 04 times. Was reduced too, the time to remove lance skulls. Lance keeps clean during all his life with record number of the life 1255 .Blow keep stable due strong measure control at the nozzles and more improvements are planning. BOF, cartridge, process control, post combustion tip life, lance skull, safety.
ANALYSIS OF GEOMETRICAL ASPECTS OF BOF CONVERTERS AND CORRELATIONS WITH PROCESS PARAMETERS
2017
Author:
Breno Totti Maia1, Willian dos Reis Lima1, 2, Romário da Rocha Nascimento.
Resume:
The continuous increase of the production steel in the last decades, caused the adjusted in steel plants in adapt in the new demand the acquiring manufactured steel. This study aimed to analyze the reactors ranging 6-350 tons of steel cast correlated their dimensional parameters and with the help of the tool data extrapolation, to propose the furnace of 800 tons. Ultimately, were checked the correlation between the important aspects as, height of boom, e slenderness ratio relation and charge/volume relation. The results show the large dimensional variation between the reactors. In some cases even with similar capabilities, the reactors are different due different manufacturers. In specific cases, the reactors have a tendency to get ideality (specific volume equal 1) or overcome with it the dimensionless level tends to decrease. The proposer reactor presented the good dimensioning and having a sharp increase in global steel demand, could be studied and implemented in the future. BOF; 800 tons’ converter; Correlation dimensional parameters; Specific Volume.
Breno Totti Maia1, Willian dos Reis Lima1, 2, Romário da Rocha Nascimento.
Resume:
The continuous increase of the production steel in the last decades, caused the adjusted in steel plants in adapt in the new demand the acquiring manufactured steel. This study aimed to analyze the reactors ranging 6-350 tons of steel cast correlated their dimensional parameters and with the help of the tool data extrapolation, to propose the furnace of 800 tons. Ultimately, were checked the correlation between the important aspects as, height of boom, e slenderness ratio relation and charge/volume relation. The results show the large dimensional variation between the reactors. In some cases even with similar capabilities, the reactors are different due different manufacturers. In specific cases, the reactors have a tendency to get ideality (specific volume equal 1) or overcome with it the dimensionless level tends to decrease. The proposer reactor presented the good dimensioning and having a sharp increase in global steel demand, could be studied and implemented in the future. BOF; 800 tons’ converter; Correlation dimensional parameters; Specific Volume.
TRIGONOMETRIC STUDY FOR BOF LANCE TIP ANGLES WITH MULTI JETS
2017
Author:
Breno Totti Maia1, Willian dos Reis Lima1, 3, Felipe da Silveira Batista1, Favrício Silveira Garajau1, Marcelo de Souza lima Guerra1, Roberto Parreiras Tavares2.
Resume:
In the present work, an analysis of geometric parameters of tip nozzles in operation was developed and extrapolations for futures situations were proposed. The main trigonometric relationships to evaluate the possibility of jet coalescence were determined. The results showed that the Primary Circle Diameter (PCD) is not affected only by the geometry of the nozzle, tips with 04 (four) nozzles and small angle with the vertical can promote coalescence and tips with more nozzles than four reduce this possibility. This work also presents a relationship between number of nozzles and angle between two adjacent nozzles. An important tool to determining conditions for development of new tips lance is proposed BOF, tip lance, angle between adjacent nozzles, PCD, coalescence; angle nozzles with vertical, number nozzles.
Breno Totti Maia1, Willian dos Reis Lima1, 3, Felipe da Silveira Batista1, Favrício Silveira Garajau1, Marcelo de Souza lima Guerra1, Roberto Parreiras Tavares2.
Resume:
In the present work, an analysis of geometric parameters of tip nozzles in operation was developed and extrapolations for futures situations were proposed. The main trigonometric relationships to evaluate the possibility of jet coalescence were determined. The results showed that the Primary Circle Diameter (PCD) is not affected only by the geometry of the nozzle, tips with 04 (four) nozzles and small angle with the vertical can promote coalescence and tips with more nozzles than four reduce this possibility. This work also presents a relationship between number of nozzles and angle between two adjacent nozzles. An important tool to determining conditions for development of new tips lance is proposed BOF, tip lance, angle between adjacent nozzles, PCD, coalescence; angle nozzles with vertical, number nozzles.
BOF BLOWING PROCESS CHALLENGES FOR HIGH RATE OF IRON ORE PELLET ADDITION - PROCESS DEVELOPMENT AND RESULTS AT TKCSA
2017
Author:
Daniel Carvelho1, Hebert Castro1, Leonardo Demuner1, Marcos Viana1, Pavel Wojnar2, Roberto Formage1, Tilo Schulz3, Dr. Breno Totti Maia.
Resume:
At thyssenkruppCSA, a positive heat balance at BOF process is faced, mainly because of low utilization of scrap and plant design. A singular logistic concept for hot metal transport between blast furnace and steel plant was established to optimize transportation and energy balance. Up to 80 kg of iron ore pellets/t steel is necessary for 340t BOF heat balance. In order to accomplish this challenge a stable blowing process, intensive operational development have been successfully executed: slopping rate reduction of 80% achieved without changing the blowing time. This paper describes steps and results of this development. BOF, LD converter, process, slopping, iron ore, addition.
Daniel Carvelho1, Hebert Castro1, Leonardo Demuner1, Marcos Viana1, Pavel Wojnar2, Roberto Formage1, Tilo Schulz3, Dr. Breno Totti Maia.
Resume:
At thyssenkruppCSA, a positive heat balance at BOF process is faced, mainly because of low utilization of scrap and plant design. A singular logistic concept for hot metal transport between blast furnace and steel plant was established to optimize transportation and energy balance. Up to 80 kg of iron ore pellets/t steel is necessary for 340t BOF heat balance. In order to accomplish this challenge a stable blowing process, intensive operational development have been successfully executed: slopping rate reduction of 80% achieved without changing the blowing time. This paper describes steps and results of this development. BOF, LD converter, process, slopping, iron ore, addition.
APLICATION OF THE SIMILARITY METHOD FOR COLD MODELING A 330 TONS BOF CONVERTER IN LABORATORY
2017
Author:
Breno Totti Maia 1, Caio N. Araújo Diniz 2, Daniel A. G. de Carvalho 3, Daniela Ladeira de Souza 4, Felipe da Silveira Batista 5, Raissa Santos Salgado 6, Roberto Parreiras Tavares 7, Romário da Rocha Nascimento 8, Willian dos Reis Lima 9. .
Resume:
Noticed the strong national and international industrial activity, more specifically concerning the steel production and the model of oxygen converter adopted on the different types of primary refining process, this work applies to relevant models, revaluating since the more rudimentary techniques till the current technologies. Then they will present the methods in which resulted the study of similarity in a converter 330 tons bringing to a 1/10 scale, allowing the realization of the studies in laboratory. Right after, will be performed an analysis comparison between simulation cold versus hot showing the benefits and drawbacks in working with the two situations. Ultimately, intends to show the deferens costs in carrying out a simulation to cold and hot simulation and also present the benefits to perform simulation in the cold model. The results obtained after the stage of discussion were satisfactory, since it allowed to reach plausible conclusions which will be of great value to companies that have the need for process improvement at low cost and without taking big risks. BOF; Modeling; Cold tests; Similarity.
Breno Totti Maia 1, Caio N. Araújo Diniz 2, Daniel A. G. de Carvalho 3, Daniela Ladeira de Souza 4, Felipe da Silveira Batista 5, Raissa Santos Salgado 6, Roberto Parreiras Tavares 7, Romário da Rocha Nascimento 8, Willian dos Reis Lima 9. .
Resume:
Noticed the strong national and international industrial activity, more specifically concerning the steel production and the model of oxygen converter adopted on the different types of primary refining process, this work applies to relevant models, revaluating since the more rudimentary techniques till the current technologies. Then they will present the methods in which resulted the study of similarity in a converter 330 tons bringing to a 1/10 scale, allowing the realization of the studies in laboratory. Right after, will be performed an analysis comparison between simulation cold versus hot showing the benefits and drawbacks in working with the two situations. Ultimately, intends to show the deferens costs in carrying out a simulation to cold and hot simulation and also present the benefits to perform simulation in the cold model. The results obtained after the stage of discussion were satisfactory, since it allowed to reach plausible conclusions which will be of great value to companies that have the need for process improvement at low cost and without taking big risks. BOF; Modeling; Cold tests; Similarity.
BOF PRESSURE EFFECTS OVER JET PENETRATION AT CSA THYSSENKRUPP
2017
Author:
Daniel Augusto Godinho de Carvalho1, Breno Totti Maia2, Fabrício Silveira Garajau2, Marcelo de Souza Lima Guerra2, Roberto Parreiras Tavares3, Shank R. Balajee4.
Resume:
BOF, due to operational conditions and location, suffer variations in the parameters whose effects on the liquid bath are usually neglected. The present paper investigated mainly two aspects: inner BOF pressure and oxygen temperature in the stagnant reservoir. The results shown that oxygen temperature changes properties like density and velocity but has small influence on jet penetration. The BOF pressure has significant influence on jet penetration and creates a new dilemma regarding nozzles dimensions considering overexpanding and underexpading jets. BOF Pressure; Jet Penetration; Oxygen Temperature, Mass movement
Daniel Augusto Godinho de Carvalho1, Breno Totti Maia2, Fabrício Silveira Garajau2, Marcelo de Souza Lima Guerra2, Roberto Parreiras Tavares3, Shank R. Balajee4.
Resume:
BOF, due to operational conditions and location, suffer variations in the parameters whose effects on the liquid bath are usually neglected. The present paper investigated mainly two aspects: inner BOF pressure and oxygen temperature in the stagnant reservoir. The results shown that oxygen temperature changes properties like density and velocity but has small influence on jet penetration. The BOF pressure has significant influence on jet penetration and creates a new dilemma regarding nozzles dimensions considering overexpanding and underexpading jets. BOF Pressure; Jet Penetration; Oxygen Temperature, Mass movement
EFFECTS OF OXYGEN TEMPERATURE AND BOF PRESSURE UNDER JET PENETRATION
2017
Author:
Breno Totti Maia1, Fabrício Silveira Garajau1, Marcelo de Souza Lima Guerra1, Roberto Parreiras Tavares2, Shank R. Balajee3; Daniel Augusto Godinho de Carvalho4.
Resume:
BOF, due to operational conditions and location, suffer variations in the parameters whose effects on the liquid bath are usually neglected. The present paper investigated mainly two aspects: inner BOF pressure and oxygen temperature in the stagnant reservoir. The results shown that oxygen temperature changes properties like density and velocity but has small influence on jet penetration. The BOF pressure has significant influence on jet penetration and creates a new dilemma regarding nozzles dimensions considering overexpanding and underexpading jets. BOF Pressure; Jet Penetration; Mass movement
Breno Totti Maia1, Fabrício Silveira Garajau1, Marcelo de Souza Lima Guerra1, Roberto Parreiras Tavares2, Shank R. Balajee3; Daniel Augusto Godinho de Carvalho4.
Resume:
BOF, due to operational conditions and location, suffer variations in the parameters whose effects on the liquid bath are usually neglected. The present paper investigated mainly two aspects: inner BOF pressure and oxygen temperature in the stagnant reservoir. The results shown that oxygen temperature changes properties like density and velocity but has small influence on jet penetration. The BOF pressure has significant influence on jet penetration and creates a new dilemma regarding nozzles dimensions considering overexpanding and underexpading jets. BOF Pressure; Jet Penetration; Mass movement
Case Study: Wear in Supersonic Nozzle of Tip Lance in Vallourec Brazil Steelmaking
2017
Author:
Fabrício Silveira Garajau 1, Marcelo de Souza Lima Guerra 2, Breno Totti Maia 3, Paulo Roberto Cetlin 4.
Resume:
This paper studies the influence of post-combustion on supersonic lance tip nozzles wear for an 80t converter, using CFD (Computational Fluid Dynamics) simulations. These analyses were based on flow profile determination of supersonic jet at minimum and maximum operation flow rates, where it could be verified post-combustion inside the nozzles at lowest flow rates. Additionally, thermal input generated by post-combustion was exported as heat flow in order to serve as a boundary condition in CFD thermal exchange simulations, also considering nozzle internal cooling. With these simulations, it was shown that copper actually reaches its melting point, at which the lowest operating flow allows post-combustion inside the nozzle. The temperature distribution profiles and the high temperatures found were also relevant for a considerable grain growth found in the wear region, according to metallographic analyses. It was thus concluded that wear occurs due to the progressive melting of copper after continuous heats with low oxygen flow rates; post-combustion inside the nozzles is the root cause for this failure. lance tip; supersonic nozzles; wear, CFD; BOF converter.
Fabrício Silveira Garajau 1, Marcelo de Souza Lima Guerra 2, Breno Totti Maia 3, Paulo Roberto Cetlin 4.
Resume:
This paper studies the influence of post-combustion on supersonic lance tip nozzles wear for an 80t converter, using CFD (Computational Fluid Dynamics) simulations. These analyses were based on flow profile determination of supersonic jet at minimum and maximum operation flow rates, where it could be verified post-combustion inside the nozzles at lowest flow rates. Additionally, thermal input generated by post-combustion was exported as heat flow in order to serve as a boundary condition in CFD thermal exchange simulations, also considering nozzle internal cooling. With these simulations, it was shown that copper actually reaches its melting point, at which the lowest operating flow allows post-combustion inside the nozzle. The temperature distribution profiles and the high temperatures found were also relevant for a considerable grain growth found in the wear region, according to metallographic analyses. It was thus concluded that wear occurs due to the progressive melting of copper after continuous heats with low oxygen flow rates; post-combustion inside the nozzles is the root cause for this failure. lance tip; supersonic nozzles; wear, CFD; BOF converter.
TBM Tuyeres Arrangements and Flow – Comparison Between BOF thyssenkrupp CSA and Cold Model
2017
Author:
Breno T. Maia1, Caio N. A. Diniz2, Daniel A. G. de Carvalho3, Daniela L. de Souza2, José Artur A. de Guimarães2, Raissa S. Salgado2, Roberto P. Tavares2
Resume:
Primary steelmaking through BOF converters represents an important point in the steel production. Against a challenger and competitive Market, operational stability and innovations are necessary to reach quality and suitable prices. In order to study the combined blowing through cold physical model, in similarity with thyssenkrupp 330t converter, visual inspection and colorimetry methods were used to define the jet penetration and the best tuyeres configuration respectively, on the metal bath behavior. It was found a distance bath lance that decreases mix time with low slopping probability. After cold model results, parameters can be recalculated for industrial practice with good agreement. Primary Steelmaking, Combined Blowing, Cold Model, Slopping
Breno T. Maia1, Caio N. A. Diniz2, Daniel A. G. de Carvalho3, Daniela L. de Souza2, José Artur A. de Guimarães2, Raissa S. Salgado2, Roberto P. Tavares2
Resume:
Primary steelmaking through BOF converters represents an important point in the steel production. Against a challenger and competitive Market, operational stability and innovations are necessary to reach quality and suitable prices. In order to study the combined blowing through cold physical model, in similarity with thyssenkrupp 330t converter, visual inspection and colorimetry methods were used to define the jet penetration and the best tuyeres configuration respectively, on the metal bath behavior. It was found a distance bath lance that decreases mix time with low slopping probability. After cold model results, parameters can be recalculated for industrial practice with good agreement. Primary Steelmaking, Combined Blowing, Cold Model, Slopping
NEW BOF PERFORMANCE AT GERDAU OURO BRANCO BY SLAGLESS® TECHNOLOGY
2016
Author:
Breno Totti Maia1, Fabrício Silveira Garajau1; Marcelo de Souza Lima Guerra1, Wellington Morais de Andrade1, Wenderson Marcial da Silva1.
Resume:
This work was a continuous and multidisciplinary development. Through studies of the blowing process and its parameters results, evolutions, improvements and adjustments were made on the lance’s hot face with Slagless® technology, as well in the process parameters and mitigating actions of the projection of materials out of the converter. The main results are the increase in the nozzle’s life with a “record mark” of 1785 heats, and water leakage occurrence in the cartridge decreased considerably reaching the mark of one year without any occurrence. BOF, cartridge, process control, tip life, lance skull, safety.
Breno Totti Maia1, Fabrício Silveira Garajau1; Marcelo de Souza Lima Guerra1, Wellington Morais de Andrade1, Wenderson Marcial da Silva1.
Resume:
This work was a continuous and multidisciplinary development. Through studies of the blowing process and its parameters results, evolutions, improvements and adjustments were made on the lance’s hot face with Slagless® technology, as well in the process parameters and mitigating actions of the projection of materials out of the converter. The main results are the increase in the nozzle’s life with a “record mark” of 1785 heats, and water leakage occurrence in the cartridge decreased considerably reaching the mark of one year without any occurrence. BOF, cartridge, process control, tip life, lance skull, safety.
Cold Model Bath Behavior Study in LD Converter with Bottom Blowing
2016
Author:
Breno Totti Maia1, Rafael Kajimoto Imagawa, Roberto Parreiras Tavares2.
Resume:
The BOF, Basic Oxygen Furnace or LD converter, is the process most widely used industrially for primary refining of pig iron today. To increase the productivity of BOF you should decrease the time of each cycle of operation, especially the blowing time. To decrease the BOF blowing time, should have a higher decarburization rate. During the blowing operation of the converter it is known that there are three stages. In the blow second stage the decarburization rate is high and constant, the limiting factor is the availability of oxygen in the bath. Thus to increase the decarburization can improve the interaction of oxygen jet with the bath. Studying the combined blow on a physical model of a LD converter 220T, has been tested different lance nozzles with a blow of 160Nm3/h and flow of 4Nm3/h and 6Nm3/h in the tuyeres. Through the tests it can be seen that increasing the number of holes in the jet nozzle, it had less penetration and the projections had a lower elevation, as by injection tuyeres effect, it increased penetration of the jet and decreased projections. It was also calculated values for the constant K for each configuration, so it is possible to predict the penetration of jet industrially BOF; Top Blow; Bottom Blown; Cold Model
Breno Totti Maia1, Rafael Kajimoto Imagawa, Roberto Parreiras Tavares2.
Resume:
The BOF, Basic Oxygen Furnace or LD converter, is the process most widely used industrially for primary refining of pig iron today. To increase the productivity of BOF you should decrease the time of each cycle of operation, especially the blowing time. To decrease the BOF blowing time, should have a higher decarburization rate. During the blowing operation of the converter it is known that there are three stages. In the blow second stage the decarburization rate is high and constant, the limiting factor is the availability of oxygen in the bath. Thus to increase the decarburization can improve the interaction of oxygen jet with the bath. Studying the combined blow on a physical model of a LD converter 220T, has been tested different lance nozzles with a blow of 160Nm3/h and flow of 4Nm3/h and 6Nm3/h in the tuyeres. Through the tests it can be seen that increasing the number of holes in the jet nozzle, it had less penetration and the projections had a lower elevation, as by injection tuyeres effect, it increased penetration of the jet and decreased projections. It was also calculated values for the constant K for each configuration, so it is possible to predict the penetration of jet industrially BOF; Top Blow; Bottom Blown; Cold Model
Continuous Developments at the Steel Plant 1 Usiminas Ipatinga Through Slagless® Technology
2015
Author:
Breno Totti Maia1, Adeilson Roberto Ribeiro2, Bruno Orlando de Almeida Santos (in memoria)1, Carlos Alberto de Souza2, Fabrício Silveira Garajau1, Marcelo de Souza Lima Guerra
Resume:
The BOF (Basic Oxygen Furnace) is most important reactor in steel production, with 53% of the total amount of steel produced around the world. USIMINAS, located in Ipatinga city, center of Minas Gerais state in Brazil, has two Steel Plants, both working with BOF converters. Steel Plant 1 has three 80-ton converters while Steel Plant 2 has two 175-ton converters. The BOF converters are steel vessels lined with refractory bricks and support for a belt that permits 360-degree rotation. The rotation allows for stages of the process such as charging hot metal and scrap and tapping steel and slag. Figure 1 shows the schematic drawing for a converter and some parameters.
Breno Totti Maia1, Adeilson Roberto Ribeiro2, Bruno Orlando de Almeida Santos (in memoria)1, Carlos Alberto de Souza2, Fabrício Silveira Garajau1, Marcelo de Souza Lima Guerra
Resume:
The BOF (Basic Oxygen Furnace) is most important reactor in steel production, with 53% of the total amount of steel produced around the world. USIMINAS, located in Ipatinga city, center of Minas Gerais state in Brazil, has two Steel Plants, both working with BOF converters. Steel Plant 1 has three 80-ton converters while Steel Plant 2 has two 175-ton converters. The BOF converters are steel vessels lined with refractory bricks and support for a belt that permits 360-degree rotation. The rotation allows for stages of the process such as charging hot metal and scrap and tapping steel and slag. Figure 1 shows the schematic drawing for a converter and some parameters.
AOD Mouth Cleaning Results in APERAM South America Using Slagless Clean Up®
2015
Author:
Breno Totti Maia1, Bruno Orlando de Almeida Santos (in memoria)1, Fabrício Silveira Garajau1, Humberto de Sousa Barcelos2, Marcelo de Souza Lima Guerra1, Maurício Ferreira Coelho2, Otávio Augusto de Cunha Teixeira2
Resume:
Nowadays the main target in most stainless steel plants is to optimize production costs. APERAM South America works with an AOD-L that started in January 2002, using an old available space around LD 2 facilities, which was shut down during that time. Carbon and electric steels are produced in an MRP-L converter. The AOD-L was installed using systems, compounds and devices that worked in the old LD. The main modifications made were: blow system, tilting, charging and dedusting system. Figure 1 shows the actual steel plant schedule in APERAM South America(1).
Breno Totti Maia1, Bruno Orlando de Almeida Santos (in memoria)1, Fabrício Silveira Garajau1, Humberto de Sousa Barcelos2, Marcelo de Souza Lima Guerra1, Maurício Ferreira Coelho2, Otávio Augusto de Cunha Teixeira2
Resume:
Nowadays the main target in most stainless steel plants is to optimize production costs. APERAM South America works with an AOD-L that started in January 2002, using an old available space around LD 2 facilities, which was shut down during that time. Carbon and electric steels are produced in an MRP-L converter. The AOD-L was installed using systems, compounds and devices that worked in the old LD. The main modifications made were: blow system, tilting, charging and dedusting system. Figure 1 shows the actual steel plant schedule in APERAM South America(1).
Earliest Leak Detection (ELD): A New
Concept of Security in Water Leak Detection
in Electric Arc Furnaces
2014
Author:
Thiago Pinto Wandekoken - Breno Totti Maia - Paulo Hopperdizel
Resume:
Water leakage from water-cooled panels in an EAF is considered to be of high operational and safety risk in the steel manufacturing process, and the early detection of the leak is an essential and necessary factor to minimize and/or eliminate such risks. Large-scale laboratory and industrial tests were carried out successfully, accrediting the technology to market.
Thiago Pinto Wandekoken - Breno Totti Maia - Paulo Hopperdizel
Resume:
Water leakage from water-cooled panels in an EAF is considered to be of high operational and safety risk in the steel manufacturing process, and the early detection of the leak is an essential and necessary factor to minimize and/or eliminate such risks. Large-scale laboratory and industrial tests were carried out successfully, accrediting the technology to market.
EOF COLD MODEL – STUDY OF BATH BEHAVIOR1
2014
Author:
Ana Clara Petrucelli - Breno Totti Maia - Gustavo Abreu - Rafael Kajimoto Imagawa - Roberto Parreiras Tavares
Resume:
O reator EOF foi desenvolvido no Brasil nos anos 80 com características únicas. O pré aquecedor de sucata e a distribuição dos pontos de injeção de gases oxidantes e combustíveis conferem estas características. O objetivo deste trabalho é reproduzir o comportamento do banho metálico de um EOF de 45t comparando seus três pontos de injeção: lanças supersônicas, lanças atmosféricas e ventaneiras. A lanças supersônicas e ventaneiras promoveram uma grande agitação do banho quando comparado com os injetores atmosféricos uma grande oportunidade de melhoria.
Ana Clara Petrucelli - Breno Totti Maia - Gustavo Abreu - Rafael Kajimoto Imagawa - Roberto Parreiras Tavares
Resume:
O reator EOF foi desenvolvido no Brasil nos anos 80 com características únicas. O pré aquecedor de sucata e a distribuição dos pontos de injeção de gases oxidantes e combustíveis conferem estas características. O objetivo deste trabalho é reproduzir o comportamento do banho metálico de um EOF de 45t comparando seus três pontos de injeção: lanças supersônicas, lanças atmosféricas e ventaneiras. A lanças supersônicas e ventaneiras promoveram uma grande agitação do banho quando comparado com os injetores atmosféricos uma grande oportunidade de melhoria.
EOF COLD MODEL – STUDY OF MIXING TIME1
2014
Author:
Bruno Orlando de Almeida Santos - Breno Totti Maia - Fabricio Silveira Garajau - Marcelo de Souza Lima Guerra - Hugo Leonardo de Freitas - Jose Geraldo Torres - Rudolf Huebner - Roberto Parreiras Tavares
Resume:
O estudo do sopro de oxigênio no EOF é muito complexo e envolve diferentes fenômenos, incluindo o desenvolvimento do jato supersônico, a interação do jato com o ambiente ao seu redor e o banho metálico, onde ocorrem importantes reações. No presente trabalho, diferentes alternativas de desenho de lança e bicos e arranjos desses no interior do EOF são desenvolvidos a interação do jato supersônico com o ambiente do banho metálico foi caracterizada. Para o EOF, o objetivo foi determinar a melhor combinação de variação de injetores e vazões para alcançar o menor tempo de mistura, estabelecendo um novo padrão operacional. O injetores tiveram pouco relevância no tempo de mistura. Ventaneiras e lanças supersônicas apresentaram os menores tempos de mistura. A lanças supersônicas tem influência nos mecanismos de movimento do banho e projeção de material líquido no EOF, enquanto as ventaneiras afetam o movimento do banho.
Bruno Orlando de Almeida Santos - Breno Totti Maia - Fabricio Silveira Garajau - Marcelo de Souza Lima Guerra - Hugo Leonardo de Freitas - Jose Geraldo Torres - Rudolf Huebner - Roberto Parreiras Tavares
Resume:
O estudo do sopro de oxigênio no EOF é muito complexo e envolve diferentes fenômenos, incluindo o desenvolvimento do jato supersônico, a interação do jato com o ambiente ao seu redor e o banho metálico, onde ocorrem importantes reações. No presente trabalho, diferentes alternativas de desenho de lança e bicos e arranjos desses no interior do EOF são desenvolvidos a interação do jato supersônico com o ambiente do banho metálico foi caracterizada. Para o EOF, o objetivo foi determinar a melhor combinação de variação de injetores e vazões para alcançar o menor tempo de mistura, estabelecendo um novo padrão operacional. O injetores tiveram pouco relevância no tempo de mistura. Ventaneiras e lanças supersônicas apresentaram os menores tempos de mistura. A lanças supersônicas tem influência nos mecanismos de movimento do banho e projeção de material líquido no EOF, enquanto as ventaneiras afetam o movimento do banho.
CFD Simulations for Water Flow
in Lance to BOF
2014
Author:
Breno Totti Maia - Bruno Orlando de Almeida Santos - Fabrício Silveira Garajau - Marcelo de Souza Lima Guerra
Resume:
• The CFD models are able to prevent and develop new performance of lance tip;
• Lance tips needs to have high velocity in the hot region or face of the tip;
• High velocity promote increase in the coefficient heat transfer;
• High coefficient heat transfer guarantee the mechanical properties of the solid materials for longer time;
• This work was applied practically into the steel shops and the results showed increase at the lance tip life by 6 times.
Breno Totti Maia - Bruno Orlando de Almeida Santos - Fabrício Silveira Garajau - Marcelo de Souza Lima Guerra
Resume:
• The CFD models are able to prevent and develop new performance of lance tip;
• Lance tips needs to have high velocity in the hot region or face of the tip;
• High velocity promote increase in the coefficient heat transfer;
• High coefficient heat transfer guarantee the mechanical properties of the solid materials for longer time;
• This work was applied practically into the steel shops and the results showed increase at the lance tip life by 6 times.
COMPARAÇÃO DA PENETRAÇÃO DO SOPRO DE
OXIGÊNIO EM CONVERTEDORES BOF COM BICOS
MULTIFUROS UTILIZANDO MODELAGEM FÍSICA1
2014
Author:
Ana Clara Petrucelli - Breno Totti Maia - Caio Nogueira Araújo Diniz - Débora Silveira - Pedro Henrique Marques Spínola de Andrade - Rafael Kajimoto Imagawa - Roberto Parreiras Tavares
Resume:
A principal ferramenta de controle do processo BOF reside na regulagem do sopro de oxigênio. A análise dos parâmetros de interação entre o sopro e o banho metálico compõe o objetivo deste trabalho. Através de uma análise visual da penetração e fração volumétrica da bacia de descarburação, foi determinada a melhor configuração de sopro entre diferentes combinações de bicos multifuros (3 a 6 furos), distância lança-banho e vazão. Foram feitas previsões sobre a penetração do jato a partir de um balanço de energia a fim de validá-las com o modelo físico. As maiores penetrações foram alcançadas com os bicos de 3 e 4 furos, com a maior vazão e menor distância lança-banho dentre os padrões testados. Todavia, as maiores frações volumétricas da bacia de descarburação foram obtidas com 5 e 6 furos, vazão e distâncias variadas dentre as ensaiadas. Palavras-chaves: BOF; Penetração de jato; Bacia de descarburação; Froude; Modelo físico.
Ana Clara Petrucelli - Breno Totti Maia - Caio Nogueira Araújo Diniz - Débora Silveira - Pedro Henrique Marques Spínola de Andrade - Rafael Kajimoto Imagawa - Roberto Parreiras Tavares
Resume:
A principal ferramenta de controle do processo BOF reside na regulagem do sopro de oxigênio. A análise dos parâmetros de interação entre o sopro e o banho metálico compõe o objetivo deste trabalho. Através de uma análise visual da penetração e fração volumétrica da bacia de descarburação, foi determinada a melhor configuração de sopro entre diferentes combinações de bicos multifuros (3 a 6 furos), distância lança-banho e vazão. Foram feitas previsões sobre a penetração do jato a partir de um balanço de energia a fim de validá-las com o modelo físico. As maiores penetrações foram alcançadas com os bicos de 3 e 4 furos, com a maior vazão e menor distância lança-banho dentre os padrões testados. Todavia, as maiores frações volumétricas da bacia de descarburação foram obtidas com 5 e 6 furos, vazão e distâncias variadas dentre as ensaiadas. Palavras-chaves: BOF; Penetração de jato; Bacia de descarburação; Froude; Modelo físico.
Effect of blow parameters in the jet penetration byphysical model of BOF converter
2014
Author:
Breno Totti Maiaa - Rafael Kajimoto Imagawab - Ana Clara Petrucellib - Roberto Parreiras Tavares
Resume:
It is important to know about the bath behavior to reduce the blow time and splashing in topof the converter. The target of this work is to compare works on the effect of twisted nozzle,flow and lance height in the jet penetration by visual inspection and by energy balancethat consider number of nozzles, vertical and twist angles. In the present work, lances withtwisted nozzle angles, normal lances and special nozzle shape were used to describe theeffects of jet on bath. Jet penetration and level of splashing were also available. For the fournozzles, the best result to reduce spitting was obtained at the twist angle, hard blow andhigh flow. High flow, reduction in bath lance distance and lower nozzle angle promoted ahigher penetration, but with bad results for the process. The energy balance showed to bea proper tool to promote adjustments in process.
Breno Totti Maiaa - Rafael Kajimoto Imagawab - Ana Clara Petrucellib - Roberto Parreiras Tavares
Resume:
It is important to know about the bath behavior to reduce the blow time and splashing in topof the converter. The target of this work is to compare works on the effect of twisted nozzle,flow and lance height in the jet penetration by visual inspection and by energy balancethat consider number of nozzles, vertical and twist angles. In the present work, lances withtwisted nozzle angles, normal lances and special nozzle shape were used to describe theeffects of jet on bath. Jet penetration and level of splashing were also available. For the fournozzles, the best result to reduce spitting was obtained at the twist angle, hard blow andhigh flow. High flow, reduction in bath lance distance and lower nozzle angle promoted ahigher penetration, but with bad results for the process. The energy balance showed to bea proper tool to promote adjustments in process.
Numerical Modeling of Flow into Primary Dedusting System of a 130t Converter
2012
Author:
Breno Totti Maia - Bruno Orlando de Almeida Santos - Fabrício Silveira Garajau - Hugo Leonardo de Freitas - Jose Geraldo Torres - Marcelo de Souza Lima Guerra - Roberto Parreiras Tavares - Rudolf Huebner
Resume:
The dedusting system is a device to control air pollution that function is to take, flow gases and fine solids. The other function is to split solids of the gases. There are two mainly types: dry systems and wet systems. In this study, the 130t LD converter has these two types. The primary dedusting is the wet system and used to take the gases direct from the converter’s mouth. The secondary dedusting is the dry system and collect fumes around converter.
Breno Totti Maia - Bruno Orlando de Almeida Santos - Fabrício Silveira Garajau - Hugo Leonardo de Freitas - Jose Geraldo Torres - Marcelo de Souza Lima Guerra - Roberto Parreiras Tavares - Rudolf Huebner
Resume:
The dedusting system is a device to control air pollution that function is to take, flow gases and fine solids. The other function is to split solids of the gases. There are two mainly types: dry systems and wet systems. In this study, the 130t LD converter has these two types. The primary dedusting is the wet system and used to take the gases direct from the converter’s mouth. The secondary dedusting is the dry system and collect fumes around converter.
New Concept of the Auxiliary Fuel Injection Tuyeres of Blast Furnaces
Developed by Numerical Simulations
2012
Author:
Bruno Orlando de Almeida Santos - Breno Totti Maia - Fabricio Silveira Garajau - Marcelo de Souza Lima Guerra - Paulo Santos Assis - José Eduardo Mautone Barros
Resume:
The injection of pulverized materials through the tuyeres of blast furnaces has been of great differential for the steel industry. Currently, the pulverized coal has become a very important supplementary fuel for generating heat and reducing the replacement of expensive metallurgical coke to reduce operating costs, stabilize blast furnace operation and reduce the emission of carbon dioxide. However, as the increased rate of pulverized coal injection (PCI), also increases the percentage of unburned coal. This material is not burned crosses the boundary of the combustion zone and is transported into the furnace, reducing the permeability of the surrounding coke and can even affect blast furnace stability.
Bruno Orlando de Almeida Santos - Breno Totti Maia - Fabricio Silveira Garajau - Marcelo de Souza Lima Guerra - Paulo Santos Assis - José Eduardo Mautone Barros
Resume:
The injection of pulverized materials through the tuyeres of blast furnaces has been of great differential for the steel industry. Currently, the pulverized coal has become a very important supplementary fuel for generating heat and reducing the replacement of expensive metallurgical coke to reduce operating costs, stabilize blast furnace operation and reduce the emission of carbon dioxide. However, as the increased rate of pulverized coal injection (PCI), also increases the percentage of unburned coal. This material is not burned crosses the boundary of the combustion zone and is transported into the furnace, reducing the permeability of the surrounding coke and can even affect blast furnace stability.
Mathematical Simulation of Blow
Through Supersonic Nozzles
2011
Author:
Breno Totti Maia - UFMG / Lumar Metals Leandro Miranda Nascimento - UFMG / Gerdau Cearense Jose Eduardo Mautone Barros - UFMG Marcelo de Souza Lima Guerra - Lumar Metals Roberto Parreiras Tavares - UFMG
Resume:
BOF Practice
Oxygen is blown into the hot metal;
Oxygen reacts with carbon of the hot metal;
Oxygen flow needs high speeds to penetrate into
high density metallic bath;
The products are CO(g) and CO2(g);
Computational Fluid Dynamics (CFD)
Velocities and pressure profiles within the domain;
Breno Totti Maia - UFMG / Lumar Metals Leandro Miranda Nascimento - UFMG / Gerdau Cearense Jose Eduardo Mautone Barros - UFMG Marcelo de Souza Lima Guerra - Lumar Metals Roberto Parreiras Tavares - UFMG
Resume:
BOF Practice
Oxygen is blown into the hot metal;
Oxygen reacts with carbon of the hot metal;
Oxygen flow needs high speeds to penetrate into
high density metallic bath;
The products are CO(g) and CO2(g);
Computational Fluid Dynamics (CFD)
Velocities and pressure profiles within the domain;
