Date of Shutdown

Start time
Duration of shutdown

Planned Shutdown of BF#2

: 5th July2014
: 6AM
: 16 hrs

Major jobs: Skip adjustment, Equalising line cleaning, Top grizzly replacement, Limit
switch of snort valve, Proper sealing of hatch cover and crown ring to avoid gas leakage,
Implementation of modified burden programme given by SDM, automation of septum
valves, Nut coke bypass provision, etc.
1. Materials for top firing i.e. fireballs, wood, diesel, match box, and clay balls to be
made ready in night shift of 4th July. They should be shifted to the place where they
are to be used.
2. Furnace should be kept hot and metal temperature should not drop.
3. Shutdown burden to be charged in night shift, as given below
4. All the weigh hoppers, receiving hopper and burden tank should be empty at time of
shutdown.
5. Last casting to be planned such that shutdown can be done by 6 AM.
6. Furnace to be drained completely at 0.8 kg/cm2, before shutdown.
7. If the burden movement is irregular or the furnace is hanging, blast pressure is to be
raised again to 1.3-1.4 kg/cm2 and forced slip should be given. Again it should be
ensured that the hearth is completely dry.
8. Shutdown to be done with a top gas temperature of about 200 degC or more and
burden level as high as possible, to facilitate top gas burning. Maintaining high top
gas temperature is a preference.
9. Little clay is to be pushed in taphole clay as the blast pressure will be low.
10. Lower the slag dam to maximum and take out as much slag as possible.
11. Purging on furnace top, dust catcher and GCP should be kept on.
12. Humidification steam to be stopped and steam manual valve should be closed.
13. Furnace to be taken off blast. There is no need to maintain gas network pressure as
project is going to do job on gas network and it has to be purged by utilities.
14. Back draft the furnace.
15. Clearance to be given for all jobs except furnace top and tuyere platform jobs.
16. Plug the tuyeres with clay ball as quickly as possible. Tuyeres should be inspected for
water leakage, before plugging.
17. Drain the main trough completely, Try to take out all the slag from the main trough
and make skimmer and bypass holes clear.
18. Give clearance for opening the cover of hatch cover manhole.
19. Fire the top gas.
20. Give clearance for BLT and furnace top jobs.
21. Clean and make cast house ready for taking the casting. If any repair job is required,
get it done with the Moonet manpower.
NOTE: Proper safety permit should be issued for each job, A-shift incharge should
ensure. Safety permits should be issued with Sl No., one copy should be kept in
control room and record of safety permit, Sl No. wise, shpuld also be maintained in
communication book

Jobs of Operation:
Inspection and plugging the tuyeres
Top gas firing
Draining the main trough, cleaning all the runners and making cast house ready
for casting.
Cleaning the equalizing line
Calibration of big sinter weigh hoppers
Thorough cleaning of skip pit and taking out all the spillages
House keeping of all the stock house, conveyor galleries, Coke sinter screen
building and transfer station.
Cleaning of railway track
Providing any support required by maintenance team
Shutdown Burden:
Aim is to regain the hearth heat, lost during shutdown, as early as possible and to
make low melting point slag with lower basicity and lower alumina to drain the
hearth properly after the shutdown.
3 coke blanks to be charged starting from 10PM(may change depending on the charge
rate)
Shutdown burden 1 to start after the extra coke
2 coke blanks to be charged again after 5 charges from start of the shutdown burden
Total charges for shut down burden1 - 20.
Material

Running burden
6400
3000

Shut down burden

1
6400
3000

Shut down burden

2
6400
3000

Coke
Centre coke(after
every 3 charges)
Sinter
Lump Ore
Pellets
Lime stone
Dolomite
Quartzite
Aim [Si]
CaO/SiO2(B2)
(Al2O3)
(MgO)
Coke Rate
Slag Rate
HM per charge, t

13700
4700
2500
0
400
400
1.0
0.99
19.26
8.79
570
356
12.58

13400
4400
2000
0
450
800
1.8
0.89
18.17
8.6
598
381
11.96

13500
4500
2500
0
500
500
1.2
0.97
18.83
9.01
580
366
12.37