project
2.
WCD hood for BOF.
This report describes a project carried out for a major steel plant in Brazil, belonging to one of the main global steel producing companies.
The plant specializes in the production of steel for various industrial sectors, including automotive, construction and general industry.
In this project, the engineering modification of the primary ventilation system of the BOF (Basic Oxygen Furnace) converters was addressed , focusing specifically on the water-cooled ducts of the first section of the ventilation system.
The main objective was to design a new, more durable and efficient duct system, capable of better withstanding harsh operating conditions and significantly reducing unscheduled downtime due to corrosion and leak problems.
About the scope of the project.
The project focused on modifying a key component of the suction system: the duct known as “Saia” .
This piece is a ring located over the mouth of the converter and, due to its smaller size compared to the complete system, it was considered ideal for carrying out a first test of the new design.
The project included redesigning the duct engineering to improve its durability as well as ensuring its compatibility with the existing assembly system.
Engineering modification of water-cooled ducts.
The main problem facing the plant was ongoing corrosion in the existing cooling lines, designed with a “tube-on-tube” system.
Due to the extreme operating conditions, the pipelines were constantly punctured , causing water leaks that disrupted the production process and required frequent maintenance.
To solve this problem, a new type of duct was designed based on a thicker inner jacket system (10 mm), with channels welded on the outside through which the cooling water circulates. This improved design offers several benefits:
- Greater corrosion resistance : By increasing the thickness of the internal sheet metal, wear caused by corrosion is significantly reduced, which prolongs the life of the ducts.
- Ease of maintenance : The design of the new ducts allows for easier repairs, as the sheet metal panels can be welded from the inside when wear requires it.
- Compatibility with the current system : The new “Saia” was designed to be completely interchangeable with the existing part, so that no changes were required in the general assembly of the suction system.
Technical analysis and adjustments made.
The project included a thorough analysis of mechanical interferences to ensure that the new part would fit properly to the converter geometry and be interchangeable with the previous design. In addition, a detailed study of cooling needs was performed , ensuring that the new conduit could handle the water flows of the current installation without significant modifications to the infrastructure.
The design also included optimized cooling circuits with 180º turns, achieved by means of chambers divided by partitions, which allowed for greater efficiency in the path of the cooling water through the external channels. This design ensures adequate cooling, preventing high temperatures that caused accelerated degradation of the previous conduit.
Results and benefits.
The implementation of the new chilled duct system has provided several key benefits for the plant:
- Increased service life : The new design has proven to be much more resistant to corrosion, reducing unscheduled maintenance downtime and prolonging the life cycle of the suction system.
- Reduced maintenance costs : By reducing the interventions required due to pipeline failures, maintenance costs have been significantly reduced, improving the operational efficiency of the plant.
- Production Optimization : With a more reliable suction system, the plant can operate for longer without interruptions, thus improving overall productivity and the ability to meet production deadlines.
- Full Compatibility : The new design integrates seamlessly with the existing assembly system, which avoided the need for additional structural modifications.
Conclusion.
This project has enabled the Brazilian steel plant to overcome recurring problems of corrosion and leaks in the water-cooled ducts of the primary suction system of the BOF converters.
The implementation of the new “Saia” design has provided a more durable and efficient solution, ensuring greater system reliability and improving the overall performance of the plant .
Thanks to the technical expertise in engineering and design of refrigeration systems, this project has achieved all its objectives, offering a robust and adaptable long-term solution.
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