~

_TECHNOLOGY

Blast FurnaceLiningand CoolingTechnology

Plate Cooler Designs Corus IJmuiden Experiences

DAN'S.' CORDS
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Preamble
This paper describes the Blast Furnace lining and cooling concept as originally
developed, applied and continuously improved by Hoogovens (Corns IJmuiden)
- The Netherlands. The technology has also been applied by Danieli Corns
('Hoogovens Technical Services') in all the Blast Furnace projects executed in
the last 25 years.
The lining and cooling technology is based on copper plate coolers surrounded
by graphitic materials that allow for good heat transfer from the hot face (burden)
to the cold faces of the copper plate coolers. Currently, there is considerable
debate and advertisement about the concept of stave cooling, either with cast
iron or copper staves. This system does increase furnace inner volume when
compared to the Danieli Corns plate design concept. However, with reduced
plate cooler length and enhanced refractory material surroundings, nearly the
same working volume can be achieved when compared to the stave concept.

Ron Stokman

This paper deals with the Danieli Corns plate-cooler lining and cooling
concept and describes the past 16 years of campaign of Corns IJmuiden Blast
Furnace No.6. The bottom and hearth have recently been repaired upon a
production of 34.3 million tons of hot metal. As expected, the Corns IJmuiden
No.6 Blast Furnace upper bosh, belly and stack design performed extremely
well and limited wear was observed in the upper bosh, belly and stack. The
lower bosh direct above the tuyere zone was worn considerably. Danieli Corns
has applied similar designs at many other plants with long campaign results
similar to that of Corns IJmuiden Blast Furnace No.6.
The excellent condition of the lining of the upper bosh, belly and stack of
Corns IJmuideIi Blast Furnace No.6 eliminated the need for repairs and the
campaign length of these zones will be extended to more than 20 years.
Egenolf van Stein Callenfels

This point was proven by Corns IJmuiden, The Netherlands, not in the least
due to their outstanding knowledge in the ironmaking field, and their pro-active
response towards sudden operational changes.
As new hearth materials are developed continuously, new Blast Furnace
campaigns of over 20 years can well be achieved using plate cooler designs
whilts high rates of pulverized coal injection are applied. In this way, the
campaign length for the entire Blast Furnace is expected to be balanced for such
a long campaign.
Tight operational tools have been used to consume temporary high heat loads
and take adequate measures to reduce these with the use of operational skills
of the Corns Ironmaking specialists.
The integrated lining and cooling concept has proven to be at least as good
as a copper stave cooling design, if not better.

Reinoud van Laar

The successful long campaign length of Corns IJmuiden Blast Furnace

proves the reliability of the plate cooling design with high conductivity
refractory materials. The results are described hereafter.

i No.6

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SEPTEMBER.

2007

IRON

& STEEL

REVIEW

_I
_TECHNOLOGY

Introduction
Coms operates two ironmaking facilities at their IJmuiden plant in The
Netherlands, Blast Furnace No.6 and Blast Furnace No.7. With only two
BlastFurnaces in operation, Coms IJmuiden has produced over 5.42 million
tons of hot metal in 2001.

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Blast Furnace No.6 has just completed its fourth (4th) campaign, with a
total production of 34.3 million metric tons of hot metal. Blast Furnace No.
6 is the smaller of the two units (See Table 1). During the last reline in 1985,
this furnace was equipped with a third tap hole and a bell-less top. The 2002
Project included amongst others a repair of Bottom and Hearth Refractories;
it was not necessary to perform any repairs on the lining above the lower bosh.

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Blast Furnace No.7 is in its third (3rd) mnning campaign, which started in
1991.The current production, at mid 2002, is around 34 million tons of hot
metal. This Blast Furnace is equipped with a traditional two-bell charging
systemin combination with a movable armour plate configuration in the throat
of the Blast Furnace.
The current campaigns are marked by several important operational events,
particularly the high productivity and PCI rates, but also by the remarkable
performance of the lining, which has shown limited wear during the first few
yearsof the campaign and hardly any reduction in thicknessduring the following
years.
This paper discusses the design of the Blast Furnaces and performance of

thedesign.

HOOHT

Blast Furnace No.6

Blast Furnace No.7

Hearth diameter

11.0m

13.8m

Working volume

2328m3

3790m3

Inner volume

2678 m3

4450 m3

Tuyeres

28

38

Tapholes

Topdesign

Bell-less top

2 bell + MA

2001 output

2.16 million tons

3.26 million tons

Start of campaign

1985

1991

End of campaign

2002

---

_.~-- - ---

TOTAL
INHER
'M)RKlHG
HEARTH

Coms' new strategy was to have only two Blast Furnaces in operation; for
that reason, this Blast Furnace was enlarged in hearth diameter, and a third
taphole and a PW top were installed.
SlPTlMBIR.2007

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running

The previous (third) campaign of Blast Furnace No.6 lasted from April
1976 to April 1985. At that time the furnace had two tapholes and the working
volume was 2159 m3. During this nine year campaign, a total of 14.0 million
tons of hot metal was produced, or 6465 thm/m3 Wv. The lining cooling
consisted of graphite, silicon carbide and copper plate coolers No repairs were
required during this campaign and the lining wear at the end of the campaign
was quite acceptable. The blowout lines showed that the wear was most severe
in the belly and lower stack.

REVIEW

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History of the Blast Furnaces

Blast Furnace No.6

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28786 mm
25'00 mm
J688 mm

I.. Rrnt 12620

Table 1 Blast Furnaces at Corus Umuiden

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.30705 mm

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Figure 1 Design of Blast FurnaceNo.

1985

6 after reline in

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I=II."""".TECHNOLOGY

The shell was partly replaced* during the 1985 reline, increasing the stack
angle from 80.7 to 83.3 and the working volume from 2159 m3 to 2328 m3
(inner volume of 2678 m3. Figure 1 shows the general arrangement of Blast
Furnace No.6 after the 1985 reline.

"

For the fourth campaign, starting in 1986, which was projected to last twelve
years or longer!, a higher production rate was envisaged as well. The stack
lining again consisted of the latest generation "Hoogovens" design of graphite
and semi-graphite in combination with Silicon Carbide refractory.The cooling
consists of a dense pattern of copper plate coolers welded into the shell.
The furnace suffered a small break-out near one of the tapholes at the end
of December 2000 after 14 years of production; this event determined the
scheduling of the April 2002 repair.
Blast Furnace No.6 has produced 34.3 million tons of iron from 1986 up
to April 2002. This amounts to 14,700 thmIm3WV for this campaign, which

is 2.25timestheproductivityper ~ of workingvolumeof theprevious(third)

campaign!
Blast Furnace No.7
The previous (second) campaign of Blast Furnace No.7 lasted from 1980
to 1991. The hearth diameter was 13.0 meters, the working volume 3615 m3.
During this eleven year campaign, a total of 25.5 tons of hot metal was produced,
or 7060 thmlm3 Wv.
The lining and cooling consisted of graphite, silicon carbide and copper
plate coolers. During this campaign, interim stack repairs were required in
1983, 1986 and 1988 due to insufficient cooling capacity (plate cooler density
too low).At the end of the campaign, the wear of the lining was quite acceptable.
The blowout lines showed that the wear was most severe in the belly and lower
stack.

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For the third campaign, starting in 1991, a campaign length of fifteen years
or more was projected. Also, a higher production rate was envisaged. The
cooler plate density in the stack was increased and it was also decided to
increase the Blast Furnace hearth diameter to 13.8 meters. The Blast Furnace

10.

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Blast Furnace Injectants

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Corus IJmuiden had introduced pulverised coal injection (PCI) on Blast

Furnace Nos. 6 and 7 in 1983. Therefore, the Blast Furnace designs had to be
able to cope with higher heat loads expected from PCI rates of around 150
kg/thm and above.
* Note: the reline provided a unique opportunity to increase the working volume - No.4 and No.5 Hklst
Furnaces were being idled requiring increased production rates of No.6 and No.7 Hklst Furnaces

<88>
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was redesigned with an increased cooling density in the middle and upper
stack and the increased hearth diameter; this resulted in a working volume of
3790 m3 (at an inner volume of 4450 m3).Again, the stack lining consisted of
the latest (fourth) generation graphite in the "Hoogovens" design of graphite
in combination with silicon carbide refractories. The cooling consists of a
dense pattern of copper plate coolers welded into the shell.
During its running campaign, Blast Furnace No.7 has produced 34 million
tons of iron from 1991 up to the spring of 2002, equaling 8970 thmlm3 WV,
already showing nearly 30% increase in productivity per ~ of working vo11;1me
as opposed to the previous (second) campaign!

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Figure 2 Design of Blast FurnaceNo.

SEPTIMBIR-2007

IRON

7 after reline in 1991

& STEEL

REVIEW

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_TECHNOLOGY

Design Features of the Danieli Corns Blast Furnaces

Danieli Corns can perform Blast Furnace designs to meet the
customer's demand for the various sections of the Blast Furnace.
Among others, the following options are available:

.
.

.
.

Bottom cooling design with air cooling or water cooling,

depending on availability of the medium;
Bottom refractory designs with big carbon blocks or small
(machined) graphite blocks (Corns IJmuiden feature) installed
without mortar;
Hearth refractory designs using big hearth blocks laid without
mortar like the Corns IJmuiden Blast Furnaces or the use of
small bricks mortared together, depending on the preference
of the customer;
Tuyere zone as highly conductive section with graphite (Corns
IJmuiden feature) or with other suitable materials;
Bosh, belly and stack of graphite only, or in combination with
other materials such as silicon carbide or high alumina,
depending on the expected campaign life of this area.

Figure 3 Installation of the lining of Blast Furnace No.6 in 1985

The following features in the Danieli Corns Blast Furnace designs proves to be an excellent tool for process control. Based on
with copper plate coolers are based on the Corns IJmuiden designs, this data, the position of the cohesive zone and its associated
which can be included in the customized Blast Furnace design by gas flows can be analysed, and based on this information,
the burden distribution can be adjusted. As such, the Heat
Danieli Corns and characterized as follows:

Flux Monitoring systemprovides an excellenttool to optimize

Process Conditions, allow for high rates of pulverized coal
injection and also allow for continuous monitoring of the
lining and cooling condition.

The hearth, which is cooled by open water sprays along the

steel shell, with safety graphite glued to the shell and large
blocks of highly conductive (micro-porous) semi-graphite
blocks;
Tuyere belt of full graphite and small Plate coolers between
the tuyeres;

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2:4-56
mea. unng p.n..I

Integrated lining and cooling system in the bosh, belly and

stack, plate coolers in combination with highly conductive
graphite;
From the belly upwards, silicon carbide bricks in the lining,
surrounded by highly conductive graphite. The quantity of
silicon carbide bricks increases in the higher areas of the
stack;
In the upper stack, up to the throat armor, a combined lining
of low alumina (chamotte) and silicon carbide with copper
plate coolers.

For process control purposes, it is recommended that the furnace

is equipped with a heat flux monitoring system. Such a system has
been engineered for and installed at the Corns IJmuiden Blast
Furnaces. The cooling system of the Blast Furnace can de divided
intro six (6) vertical zones (bosh, belly, lower stack, lower middle
stack, upper middle stack and upper stack).Each zone is then divided
into eight (8) horizontal sectors in circumference. Hence, there is
a total of 48 sectors in the bosh and stack. The number of sectors
can be adjusted for each Blast Furnace design.

Figure 4 Heat Flux monitoring of Blast Furnaces

Pulverized Coal Injection and Blast Furnace Productivity

The injection of pulverized coal into Blast Furnaces Nos.

6 and 7 started in 1983. The system was originally designed
for an average coal injection level of 90 kg/thm. The PCI
technology and injection rates were steadily improved in
order to be less dependant on in-house coke production. To
develop the high PCI technology to levels above 200 kglthm,
a nine (9) months trial was carried out on Blast Furnace No.
6, starting in April 1992. The trial also demonstrated the
In each sector, the heat flux is measured continuously. This data economic viability of a third grinding line. A PCI level of

mON & STEEL REVIEW SlPTlMBER.2007

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I:II

TECHNOLOGY

190 kg/thm was targeted since this matched the available PCI rate
when a third pulverising line would be added.
As a result of careful preparation, the constant attention to process
control and the constant quality of burden materials, the trial was
very successful.The careful increase of the PCI rate from 135kg/thm
to 190 kg/thm took two months. During five (5) months, the PCI
rate was maintained at 190 kg/thm and because of the good results
and the significant process stability, it was decided to increase the
PCI rate to 210 kg/thm. The coke rate (including nut coke) dropped
to 272 kg/thm at a PCI rate of 212 kg/thm2. The theoretical
replacement ratio of the injected high-volatile USA coals was 1.1.
Feb '92
I

Dec '92 Feb '97 Oct '02

6820

6700

23.6

246

264

41

36

47

22

kg/thm

134

212

218

216

k/thm

485

484

511

504

Equiv.87.5%Ccoke kg/thm

475

466

482

469

Production

tlunl24hrs

Fuels:Coarse coke

kg/thm

3.10

Smallcoke

kg/thm

PCI
Total

Blastvolume

Nm3/min

4230

3492

3922

3748

Totaloxygen

22.8

26.6

29.1

32.2

Gasutilisation

48.1

48.5

48.1

48.6

Hot metal: Si

Si st. dev.
Temperature

0.40

0.3.6

0.41

0.3.9

0.08

0.08

0.11

0.06

1507

1495

1504

1522

Figure 5 PCI injection lances and optical blocktector devices

around the Blast Furnace

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The major contributors were:

.
.
.
.

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Robust furnace cooling and lining design that could handle

any occurring heat load;
Consistent coke and burden quality;
Improvements in process control and burdening practice;
A combination of pC! and oxygen enrichment of the hot blast
to enable a considerable decrease of the stack gas volume.

This last item compensated for the increase in burden resistance

caused by the high PCI rates, which is due to the increased pulverised
coal with respect to the amount of coke in the Blast Furnace. The
oxygen enrichment, however, is limited due to the need to have
sufficient gas flow available for the drying process of the burden
in the upper furnace.

<90>

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'86

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20
'90

'94

'98

'02

Figure 6 Evolution of productivity and oxygen in the blast

Table 2 PCI trials in 1992 and 1997 results at Blast Furnace No.
6, and common practice as shown in October 2002
The productivity of Blast Furnace No.6 shows a steady increase
since 1986, as shown in Figure 6. Today, a productivity of over 3.0
t/24hr/m3 WV is standard practice, owing to a PCI level of well
over 200 kg/thm even up to 230 kg/THM. Many factors, from
furnace design to process control were accountable for this trend.

30

400

"
~~

~6

200

0
'86

'90

'94

'98

'02

Figure 7 Consumption of Coke and Coal in Blast Frunace

Ironmaking

Lining Wear Measurements and Experiences

In the stack of both Blast Furnaces at Corus IJmuiden,
ceramic rods are integratedinto the lining for lining thickness
monitoring. Based on the principle that these rods will wear
at the same rate as the lining, their length is a good indication
of the residual thickness of the lining.
The length of the rods is measured ultrasonically during
each major stop.
Blast Furnaces Nos. 6 and 7 have several levels of ceramic
rods in the belly and stack. There are three rods per level,
approximately 1200apart. Each rod is positioned between
the plate coolers at the location where the highest wear is
expected.
SEPTEMBER.

2 007

mON

& STEEL

HEVIEW

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TECHNOLOGY

During normal stops the rod nozzle caps are removed and the
length of each rod measured using an ultrasonic device. Physical
thickness measurements are carried out when a rod is replaced in
case it is broken, and also during plate cooler changes. These physical
measurements confirm that the ultrasonic measurements are reliable.

As an example, Figure 9 shows the history of the lining thickness

in the upper belly. The thickness is measured from the inside of the
shell. The insertion depth of the plate coolers is 500 mm (20") and
the original lining thickness is 600 mm.

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As the graph shows, the lining in front of the cooler noses has
disappeared after approximately one year. After about four years of
operation, the wear has stabilized at a thickness of approximately
380 mm.

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With a worn stack lining and the plate cooler noses exposed, the
furnace lining and cooling concept is capable of coping with high
heat loads up to 500,000 W/m2.This was confirmed in 1994 during
a trial with a 100% pellet burden3at Corns Umuiden. The extremely
high heat fluxes and fluctuations related to this burden practice
during this trial have not led to noticeable wear.
The maximum heat flux measured in the belly and the lower stack
area was 410,000 W/m2 based on five minutes data intervals. This
shows that the Corns IJmuiden design lining and cooling system is
veryforgivingwith respect to high heat loads. Moreover,the selection
of a graphite lining made it possible to cope with very high heat
load fluctuations without spalling the refractories.

Figure 8 Ceramic Rod Lining Thickness Measurement

60

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40

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'90

'94

'98

'02

Figure 9 Corus Umuiden No.6 Blast Furnace upper

Belly lining wear versus campaign length

Measurements from the ceramic rods and the additional physical

measurements show that the minimum average lining thickness is
360 mm in the top of the belly. The minimum value of all
measurements is 330 mm.
Lining Condition after 16 Years

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The remaining thickness of the hearth wall showed that Corns

IJmuiden had selected the right moment to repair the hearth of No.
6 Blast Furnace. Especially under and adjacent to the tap holes, all
of the semi-graphite material had disappeared and even some of the
safety graphite was affected by iron.
Hearth Bottom

Figure

10 Bottom and Heart Wear Lines

The bottom wear condition was more or less as expected. The

high alumina top layer was dissolved, as well as the complete layer
of semi-graphite below the mentioned layer. Approximately half of
the original installed high conductivity graphite had disappeared as
well. Since Corns IJmuiden have designed their furnaces with a
shallow hearth, this wear profIle could be expected after a production
period of sixteen years.

The safety lining performed well providing sufficient

protection to the steel shell after the hearth semi-graphite
lining had disappeared. Without this safety lining, the risk
for a breakout had been much higher in the end of the
campaign. Together with intensive thermal monitoring of
the most worn area, it was possibleto maintainfullproduction
up to the end of the campaign.

Hearth sidewalls

Thyere Area

The hearth showed heavy "elephant foot" wear. In the vicinity of

the three tap holes, almost all of the hearth semi-graphite hot face
lining had been worn completely. Since the tree tap holes are located
rather close to each other, a long section of the hearth was worn that
way. What was left was the safety graphite lining directly against
the steel shell.

The tuyere area was worn at the upper half of the tuyere
blocks and for a larger part disappeared. In Corns Umuiden's
opinion, the main reason was a somewhat insufficientcooling
capacity in this critical area. It was decided to increase the
cooling density in this area and to install one extra row of
plate coolers above the tuyeres: this extra row should also

IRON & STEEL REVIEW

SEPTEMBER-2007

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_TECHNOLOGY

provide better protection to the tuyeres. For practical reasons, it was

decided to demolish all tuyere block refractories.
i'

Bosh, Belly and Stack

The graphite/semi-graphite refractory directly above the tuyere

zone (lower bosh) had also disappeared considerably up to row 3-4
in the lower bosh. Especially the semi-graphite had been worn.
Therefore it was decided to replace the semi-graphite with graphite.
The remainder of the bosh, belly and stack showed a remarkably
good condition.The refractory lining had only worn varying between
50 and 150 mm behind the noses of the plate coolers.
During the campaign, no maintenance to the lining needed to be
perfonned. The lining and cooling concept of these sections showed
that under varying operational conditions (see above), this design
concept could even withstand high and severely fluctuating heat
loads up to 410,000 W/m2.
Figure 11and Figure 12 on the followingpages show the condition
of the bosh, belly and stack lining and cooling after 16 years.
Considering recent experiences, it is expected that the bosh, belly
and stack campaigns can be further prolonged to more than 20
years. Although some copper coolers will have to be replaced
because of prolonged abrasive wear of the noses, it is noted that
this can be done during normal maintenance
stops4.

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Middle Stack

Hearth Design
Coms IJmuiden has selected the use of (micro-pore)
semi-graphite in the most critical zones of the Blast Furnace
from the start of the hearth until the top of the taphole blocks,
with a back-up of safety graphite glued to the steel shell.
Above this area, semi-graphite and safety-graphite are
installed over the remaining height of the hearth. This fourth
generation micro-pore semi-graphite must bring the lifetime
of the under hearth to the same length as the other sections
of the Blast Furnace. See Figure 13 for the latest design
install~d at Corus IJmuiden Blast Furnace No.6.

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The high conductivity of the hearth materials resulting

in low hot face temperatures, reducing or limiting
thennal expansion and sensitivity for chemical attack;

Low iron content to reduce CO disintegration;

Micro-porous material to limit iron penetration.

Installation of Refractories

- --- ---I

Figure 11 Remaining Lining Thickness in Bosh and Belly

The installation of all refractories in the bottom, hearth,

tuyere zone and raceway was done in a tight fit generally
without the use of mortar. This was done to obtain the most
effectiveheat transfer between the semi-graphite, the graphite
SEPTEMBER.2007

<92>
--

IRON

& STEEL

REVIEW

_TECHNOLOGY

The Blast Furnace can therefore reliably

be driven to the unknown limits of
production and PCI injection, which is
exactly what the operators wish to achieve.
Current productivities up to 3.0 thmlm3
WV /24hrs and over can be achieved at a

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constant hot metal quality with a traditional

burden composition.
However, the success of the long and
continuing campaign life is not only
accountable to the excellent design of the
Corus IJmuiden Integrated Lining and
Cooling System. The knowledge gained
through investigations and long-term trials
on the furnaces have been translated into

GRAPHITE

SEMI-GRAPHIre
MlrnOPOREMI-GRAPHITE
CARBON

SIlliMANITE

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operational
procedures
for high
productivity at acceptable heat losses. In
addition, coal injection rates of up to 230
kg/thm are accepted as standard practice.
Figure 13 Corus Umuiden Blast Furnace No.6 Hearth Design

and the shell. However, the lower bosh replacement material was
also mortared to be able to re-store contact between the retained
and new refractories. All refractories were installed with expansion
allowances in order to reduce/minimize stress levels in the materials.

It is clear that the Corus IJmuiden

Design Department and the Operating Staff and Crew are
proud of the achievement of their Blast Furnaces after
impressive years of production.

The refractories in the middle and upper bosh, the belly and stack
remained untouched.

The teams are aware of the fact that the continued

campaigns will bring world records to the iron and steel
industry, never shown before.

Conclusions

References to Literature

The latest experiences at Blast Furnaces Nos. 6 and 7 of Corus

IJmuiden are clear evidences for the excellent performance of the
plate-cooledlining and coolingconcept selectedin the early seventies
and improved and optimized over sub-sequential campaigns. This
state-of-the-art design has now achieved a campaign length of
sixteen(16) years without any interim repairs to the bosh, belly and
stack.

We would like to thank the authors of-the articles

mentioned below.Furthermore, the publication 1 in 1997
was the basis of this updated paper. Special thanks go to
Messrs. G. Tijhuis and H. Toxopeus for their appreciated
contribution to the issue of this paper. We also like to thank
the BF Management (i.e. BF Works Manager Mr. R.
Molenaar) for the use of their operational data and files.

Due to the replacement of refractories for the bottom, hearth,

tuyeres and lower bosh, Blast Furnace No.6 has run into a new
fifth (5th)campaign from June 2002 onwards. For the major bosh
part, the belly and the stack, Blast Furnace No.6 has ~ontinued its
17thyear of its fourth running campaign with already a productivity
of 14,700thmlm3WV (12,810 thmlm3 IV) up to the spring of 2002
for that bosh part, belly and stack. It is expected that a considerable
number of years can be added to the campaign legth of the bosh,
belly and stack refractories whilst the new bottom and hearth
refractories are anticipated to achieve at least sixteen (16) years
agam.
Blast Furnace No.7 has completed eleven (11) years of its third
(3rd)running campaign and it is expected that this Blast Furnace
will also achieve at least the same length of campaign as Blast
Furnace No.6.
The lining and cooling system of the bosh and stack is very
forgiving with respect to high heat loads and process deviations.
IRON & STEEL REVIEW

SEPTEMBER-2007

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