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Research and Development Background
In recent years, the global trend towards a low-carbon economy and the increasingly severe climate issues have garnered significant attention. China has proposed the construction of resource-conserving and environmentally friendly enterprises. In the metallurgical industry, the energy consumption and pollution generated by blast furnace ironmaking account for a large proportion of the entire steel production process, making it a key target for energy-saving and emission reduction measures.
During the blast furnace smelting process, the equalizing gas in the top bin of the furnace is usually discharged directly into the atmosphere after passing through a cyclone dust collector and silencer. This gas contains a large amount of CO and dust, making it a toxic and combustible mixture that pollutes the atmosphere, especially the blast furnace production area, while also wasting energy.
Our company's research and development of the blast furnace top gas equalizing pressure recovery technology has been successfully applied to multiple blast furnaces with good results. The technology quickly recovers costs and addresses issues such as high dust content in discharged gas, large pressure fluctuations, short lifespan, and pollution of the clean gas network, which were difficult problems for previous gas recovery technologies. This technology meets environmental protection requirements.
Process Flow
Application Scope
The furnace top balanced pressure coal gas recovery device does not occupy the limited space of the furnace top or increase the load of the furnace top frame. It features a simple structure, easy arrangement, and high safety:
At the same time, it has good dust removal effect, recovers clean coal gas, and the recovered gas directly enters the clean gas pipeline network. It minimally pollutes the clean gas pipeline network and has almost no impact from pressure fluctuations, thus maximizing the reduction of toxic gas emissions and achieving true environmental protection.
This technology can be applied in new construction and renovation projects. Project sites are usually limited and narrow. This recovery device can be used for new construction or can be retrofitted to existing surplus dry dust removal systems with simplified design.
Process Selection
The balanced pressure coal gas recovery process is divided into two types: partial recovery and full recovery.
Partial Recovery
Before charging the furnace top bunker of the blast furnace, the pressure inside the bunker is consistent with the furnace pressure, in a high-pressure state. The coal gas recovery device connected to the atmospheric coal gas pipeline network maintains atmospheric pressure inside. By opening the coal gas recovery valve between the bunker and the recovery device, gas discharged from the bunker is recovered using natural pressure differentials. When the pressures inside the bunker and the recovery device meet the conditions for opening the charging valve or achieve balance, the coal gas recovery valve is closed, and the recovery process ends. The remaining gas in the bunker, close to atmospheric pressure, is released according to the blast furnace charging procedure to reduce bunker pressure to less than 5 kPa. This process is known as 'partial recovery'.
Full Recovery, after the partial recovery process
Method 1: Using a jet pump device, residual pressure coal gas in the bunker is driven into the recovery device using high-pressure clean coal gas through jet suction effect. After the bunker pressure drops below 5 kPa, jet suction is stopped, the coal gas recovery system valves are closed, and the upper dense valve is opened for charging.
Throughout this process, the release valve remains closed, preventing gas release from the intermediate bunker and achieving full recovery of the gas.
Method 2: Using a hot blast stove smoke backflushing process, atmospheric pressure coal gas in the bunker is driven into the balanced pressure coal gas recovery equipment, achieving full recovery of balanced coal gas and zero emissions of CO. After backflushing, smoke from the bunker still needs to be released to reduce bunker pressure to less than 5 kPa.
This process utilizes backflushing to achieve maximum recovery and utilization of coal gas.
Technical Level
The main design technical specifications of the balanced pressure coal gas recovery device are as follows (specific indicators vary with different process forms):
★ Meets gas purification requirements, gas dust concentration <5 mg/Nm3.
★ Full recovery of coal gas; balanced pressure release valve remains closed, zero emissions from balanced pressure release (bunker pressure below 5 kPa).
★ Equipment operation noise <85 dB(A) (valve noise).
★ Construction and operation of the balanced pressure coal gas recovery system do not affect the normal production of the original gas purification system and blast furnace process system.
★ According to actual blast furnace production processes, charging batches, and times, reasonable planning of recovery time, injection time, and design of balanced pressure recovery systems and dust collectors ensure that blast furnace production is not affected.
Technical Features
Technical Challenge - Condensation Water Issue:
After the blast furnace coal gas balanced pressure recovery system is put into operation, during the recovery process, which involves pressure reduction and cooling of the blast furnace coal gas, moisture in the gas can condense and combine with dust in the blast furnace gas, forming a viscous wastewater mixture.
Impacts
Bonding of filter bags, reducing their lifespan, affecting gas purification efficiency, and failing to meet environmental purification requirements.
Periodic ash removal from dust collectors results in wet ash that cannot be discharged properly, causing significant impacts on pneumatic conveying or other ash discharge methods.
Solution
One solution is the application of the intermediate bunker of the blast furnace top charging equipment with Patent Certificate No. ZL201921943859.0, utilizing companion heating technology;
This technology maintains the recovered coal gas above a certain temperature at all times, preventing condensation water formation and thereby protecting filter bags.
Ultimately, it achieves truly dry ash removal, meeting any ash discharge or conveying requirements effectively.
Application of Injection Technology
Based on the familiarity and understanding of blast furnace production processes by our professional team, the design of the balanced pressure recovery system is specifically tailored to the production rhythm of existing blast furnaces. The design and planning of the recovery process ensure that it does not affect the charging rhythm of the blast furnace.
Thorough verification and theoretical validation are conducted for the injection system and the medium used for injection in existing blast furnaces (such as high-pressure coal gas or fluorine gas). This is done in conjunction with successful operation practices of multiple balanced pressure recovery systems, ensuring effective injection and achieving full recovery.
Idle Blast Recovery
Idle blast in a blast furnace refers to temporarily ceasing the operation of supplying air into the furnace, which is a necessary measure in iron smelting production.
Using a bell-less top device, in previous idle blast operations, raw coal gas and dust were directly discharged into the atmosphere for durations ranging from 5 minutes to 30 minutes or longer (according to process requirements). Typically, after reaching a certain pressure value, the furnace top or gravity dust removal release valve is directly opened for gas release operations. Although the emission rate meets requirements, it can lead to yellow smoke emissions from the blast furnace top or gravity dust removal components.
The objective of this particulate matter control project is to address the unorganized and disorderly emission of smoke and dust during blast furnace top releases. It proposes an efficient and reasonable solution using the principle of jet suction to improve current idle blast operations effectively.
This plan involves constructing a new idle blast pipeline, modifying the balanced pressure coal gas recovery dust collector housing and jet suction device for idle blast gas recovery operations. Above the shut-off valve of the coarse gas pipeline at the entrance of the gravity dust collector or in front of the furnace top release valve, a new idle blast coal gas recovery pipeline entrance and matching valves are installed. The advantage of the interface in front of the furnace top release valve is that it eliminates concerns about coating inside the pipeline, and the furnace top platform can serve as the valve layout operation area without the need for a new valve platform.
The newly constructed idle blast connection pipelines and valve groups are all connected to the existing balanced pressure coal gas recovery pipeline, then introducing gas into the existing blast furnace gas bunker balanced pressure recovery dust collector, retrofitting this balanced pressure recovery dust collector to save investment.
For the dust collector outlet modification, two new recovery pipelines are built. The first recovery pipeline directly connects to the low-pressure network. When the idle blast coal gas pressure is higher than the low-pressure network, natural recovery operations are conducted. Utilizing the pressure difference, the purified blast furnace gas flows naturally into the low-pressure pipeline, and the original blast furnace gas bunker balanced pressure recovery can also use this pipeline. When the pressure is below 30 kPa, the valve of the first recovery pipeline is closed, and gas is introduced into the second recovery pipeline. The second recovery pipeline is a jet suction pipeline that uses high-pressure ammonia gas for jet suction operations. High-pressure ammonia gas from the existing ammonia gas pipeline is introduced into a newly constructed nitrogen tank of 10~15 m3 (determined based on blast furnace volume), and jet suction operations are conducted through pressure reduction and valve adjustment to collect the remaining gas into the low-pressure network. The entire system and recovery pipelines can be renovated using the existing balanced pressure recovery system and pipelines, which results in low investment, good effectiveness, and minimal operating costs and nitrogen gas consumption.
Zero Emission of Blast Furnace Gas
In the original blast furnace production process, the system for gas release through the release tower is reformed. Through collaboration with Shougang Environmental Protection Department's patented technology, a water sealing device is added to achieve zero leakage of gas during normal operation.
Company Profile
Vision
With dees of rapid development and accumulation, China has been perfect and mature on technology and management in various industrial areas, shaping a complete processing manufacturing industry with competitive price, well known for its excellent skill, high efficiency and hardworking team with qualification for personnel dispatching.
| Professional Professional technical and management team with abundant experience in the implementation of domestic and international projects; |
| Responsive Responsively and meticulously, translating your needs into complete solutions; |
| Integration Integrating various technologies and resources in China and fulfilling complementary advantages, by relying on professional teams; |
| Motivation Motivated to provide the optimal solution and quality products; |
| Exceptional Exceptional, delivery and,implementation of projects to meet, your expectations; |
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