BLT Operation – Logics

Charging of material into furnace starts from Discharging of materials from Bin into weighing
hopper for lower coke rate and high productivity.

Operator has to know the availability of material and the quantity of material to be taken for each
charge before setting value for each material, by proper calculations. Once calculations are over
and confirmed by senior person, then he can proceed further.

When operator gives the set value, he has to ensure any time delay is to be set for any material,
depends on furnace aerodynamics, especially for iron bearing material and flux

And once set, he has to ensure whether it is batching as per set value in the matrix and time delay
or not.
And if batched more or less, he has to also ensure the error is corrected or not in immediate next
charge. And if not, he has to inform to senior immediately. The matrix of the stock house is given
as below.

Note: He has to know the materials, and analysis of each bunker.

When materials are discharged from weighing hopper, it should be ensured all the weighing
hoppers are discharged as per the matrix or not. Operator can choose one set of matrix or
two/three as per his requirement. Now material is ready in centralized hopper for discharging
into skip.

RMHS Matrix

10 9 8 7 6 5 4 3 2 1
Bin No

Sinter Sinter Sinter Ore Ore Ore Ore Sinter Sinter Sinter
Row 1

Additiv Additi Coke Coke Coke Coke Additi Additi N.C

Row 2

1222 1222
Coke 1

1222 1222
Coke 2

1500 0 1500 800 800

Ore 1
0 0

800 900 1500 1500

Ore 2
300 300 400

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Discharging of Material into SKIP:-
When skip reaches its position and feedback comes then only centralized hopper gate will
open. And skip will lift only when centralized hopper gate close feedback comes.

Then, centralized hopper will be made ready for next batch.

And skip will reach to dumping position only when the receiving hopper is ready for next
charge. Otherwise it will be stopped at mid way.

Now the operator should know all the terminologies of Bell Less Top to have clear
understanding. In Bell Less Top the following parts are there. They are as follows;-

Equipments & Interlocks

Receiving Hopper (RH): - To receive the charge or burden materials as sent by the
stock-house via the skip conveyor. It’s the top most part in Bell Less Top.
Interlock
It will give command to dump next skip material if (1) only one skip of material of the
same class is there in skip or
(2) if different class of martial is there, it will give command to skip if RH is empty and
UMG is in closed position

Upper Material Valve (UMG): -

It acts as protection to upper seal valve, during receiving of material into receiving
hopper. It has been placed just at the bottom of the receiving hopper.

Interlock: -
Upper Material Gate Opens if: -
Upper Seal valve is open
Dumping of skip is over

Upper Material Gate Closes if: -

Receiving Hopper is empty signal is received

Upper Seal Valve (USV):- It has been placed between Upper Material Gate and
Discharging hopper. It maintains the furnace top pressure inside the Discharge Hopper
during the discharge of materials from discharge hopper into furnace. It will open before
UMG and Close after closing of UMG

Interlock
Upper Seal Valve will close if: -
The material transfer is completed in receiving hopper signal to be received
Upper Material Gate is in closed condition
The Equalizing valve is closed
Lower seal valve is closed
Relief valve is opened and atmosphere pressure is achieved

2
Upper Seal Valve will open if: -
Lower seal valve is closed
Lower material gate is closed
Equalizing valve is closed
Relief valve is opened and atm pressure is achieved

Note: LSV and USV cannot be opened at a r same time otherwise in emergency where
furnace top pressure is less than .15 kg/cm2

Discharge Hopper (DH): - It collects the materials from receiving hopper and helps in
discharging of materials into the furnace in a controlled manner. It’s placed between USV
and Lower Material Gate. Its volume is 18 m3

Lower Material Valve (LMG): - It discharges the materials in to the furnace in a

controlled manner, to reach out to all the areas of the furnace. It also acts as protection to
Lower Seal valve. It has been placed between DH and Lower Seal Valve.

Interlock
Lower Material Gate Can be Opened if: -
Lower Seal Valve is opened
Stock rod is in locking position
The Charging level is reached
The Chute is tilted to dumping angle and chute rotation feedback is coming

Angle of LMG for Different Quantity of Coke

No of
Rotations Quantity Of Coke
4100 4300 4500 4700 4900 5100 5300 5500 5700
5
6
7
8 24 24 24 24 24 24 24 24 24
9
10
11
12
13

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Angle of LMG opening for Different Quantity of IBRM

No of
Rotations Quantity of IBRM
9100 10250 11400 12550 13700 14850 16000 17150 18300 19450 20600 21750 22900 24050
5
6
7
8 22 22 22 22 22 22 22 22 22 22 22 22 22 22
9
10
11
12
13
14

LMG can be Closed if: -

The discharge hopper empty signal is received
And LMG opens completely

Lower Seal Valve (LSV): - It maintains the furnace top pressure and blocks the BFG
and materials coming into Discharge Hopper during materials transfer from receiving
hopper in to discharge hopper. It will open before LMG and Close after closing of LMG.

Interlock
Lower Seal Valve can be Opened if: -
Upper Seal Valve is closed
Relief Valve is closed
Equalizing valve is opened and furnace pressure is achieved

LSV can be closed if: -

Lower material gate is closed
Upper Seal Valve is closed
Relief is in closed condition
And Equalizing in open condition

Equalizing Valve (EV): - It equalizes the discharge hopper primarily with BFG near to
furnace pressure and closes and N2 is used to reach the Discharge Hopper to get 0.05kg
more than the Discharge Bin Pressure. It will be in closed condition during change over
of material from RH to DH
Interlock
Equalizing valve opens if: -
The relief valve is closed
The upper seal valve is closed

Equalizing valve closes if: -

LMG is opened and material is started to discharge

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Relief Valve (RV): - It will be kept open during transfer of materials from Receiving
Hopper to Discharge Hopper and kept closed during equalizing of Discharge Hopper and
discharge of materials/burden into furnace
Interlock
Relief valve can be opened if: -
The equalizing valve is closed
LSV is closed

Relief valve can be closed if: -

If USV is closed. (This is must when lower seal valve is leaking)

Discharge Funnel: - The discharge funnel is connected to the lower flanges of the valve
activation unit and it guides the materials to be discharged from the Discharge Hopper
into the vertical feeder spout, which is located along the axis of the blast furnace

Distribution Chute & its Suspension and Interlocks:-

Material is distributed into the furnace via the distributing device, which has two
motions, i.e. Tilting and Rotation. The working angle for the distribution chute is 8-29.
Chute rotation is fixed, but fixed anywhere between 0-11rpm. We will fix at 7.5
sec/rotation. The distribution of Material will be done as per the given below matrix

Note: The selection of angle and no of rotation on particular ring is operator decision,
which will be based on furnace movement and uptake temperature and gas profile

The chute is suspended to the suspension bin of the chute angle adjusting gears, just
below the cylindrical feeder spout

Primary Equalizing valve will close when the DH pressure is almost equal to the furnace
pressure

The secondary equalization closes as soon as the LMG starts closing.

Stock rods can be lowered if the materials gates are closed

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 Material Distribution inside the Furnace Matrix
Ring No 1 2 3 4 5 6 7 8

Angle 5.71 13.82 17.77 20.83 23.25 25.44 28.30 29.14

Distance
from .795 1.125 1.377 1.59 1.77 1.95 2.1 2.25
Center
Center .
of the .398 0.96 1.251 1.484 1.676 1.856 2.023 2.175
ring
Coke 2 1 1 2 1

Ore 1 1 2 2 1
Coke 1 1 1 1 1
Ore 1 1 1 2 1
Coke 2 2 1 1 1
Ore 1 1 1 1 1

Dumping into Furnace:- We should always maintain the level of the furnace to
maximum gas utilization. So, we should keep the furnace stock level at 0.8 m to 1.2 to m
from zeroth metallurgical level of furnace, depends on the furnace movement.

To measure this, we use continuous stock line measuring sensors. This will move down
along with the burden materials. When it reaches the set level of the stock line, it will get
the command from PLC to be lifted upwards. While its getting lifted upwards, it requires
display of the following parameters ready for verification.

Display of stock rod lock in position (At least one rod must bge in Operation)
Display of distribution ring and no. of rotation on each ring
Display of timer and the timer should start when the Lower Seal Valve Opens
Display of Chute rotation and at the inclination angle of chute

Note: - If stock level is below off rod, sock rod should be lifted upwards and kept in
parking position, till the Discharge hopper is getting ready

Before getting this, Discharge Hopper will be in Pressurized conditionAnd ready for
discharge. And the above condition are satisfied

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