hrc by xiaoyounan


									Application and Technology Research of HM-HRC
  Technology on Hot Stove Regeneration of BF

One time investment. Takes back within half a year.
               Benefits for 30 years.

 Shandong Huimin Science & Technology Co,. Ltd.
                 Jinan, Shandong, China
              86-531-88061276   86-13906401517

Brief Introduction of Inventor:
    Huimin Zhou, lady, board chairwoman of Shandong
Huimin Science and Technology CO., LTD. Postgraduate,
engineering technology application researcher, senior
engineer, subsidy beneficiary of the State Council
Government. National 12th and 13th Antarctic Expedition
Member. The foreign nationality expert member of
American Iron & Steel Institute. She obtained the
bachelor degree from Beijing Steel College in January 1982
and master degree of business administration from
Southern Cross University of Australia in March 2007.
    She has always been engaged in the technique research
of material and material surface, obtained more than 20
scientific achievements, 11 patents, published 15 academic
papers both in China and abroad. She is committing
herself to the High Radiative Coating Technology
Research at present. The inventor of High Radiative
Coating Technology,a new inventive technology which
integrates metallurgy, material and chemical to one
subject, it is a breakthrough in iron making and energy
saving technology which makes the technology keep the
first level in the world.

What is HM-HRC Tech ?
    HRC Tech ( High Radiative Coating
Tech) coats a high radiative rate material
on the material surface which strengthen the
heat radiation absorption and radiation
ability, improve the radiation heat transfer
HM-HRC is a surface treatment tech.

 Surface treatment tech. is a system engineering:
 Surface coating, surface structure, stress state
 and chemical property reform in order to
 obtain a desire surface quality.
 The coating tech. consumes few coating
 material, obtains satisfactory results including
 the high economic benefit due to without
 operation cost etc.
  Principle of HM-HRC Tech.

       Heat transfer models :convection, radiation, conduction.

The temperature of hot stove is 1300℃,radiative heat transfer account
to 85% of the gross heat flux since the high temperature dissociative
carbon which was generated during the gas combustion has strong
radiative capability.
Based on the law of Steifen-Bolzman: E=ε0 C0(T 100 )4
Principle of HM-HRC Tech.
                                  Radiative rate ε
Most of the high temperature       1.0
radiation energy concentrate in
1 ~ 5 um wave range. For           0.8

example, 76% and 85% of the                                                      3
                                   0.6                                           2
radiation energy concentrate in                                                  1
the wave range when the
temperature reach to 1000℃
and 1300℃ respectively. The
                                                           1. Clay castables
radiative rate of common           0.2                     2. High-alumina bricks
                                                           3. Clay refractory bricks
                                                           4. Higher radiative rate coating
refractory is low in this wave
range (fig 1), in contrast the           0   2   4     6       8 10
                                                     Wavelength / μm
                                                                             12 14 16

high radiative rate coating has
                                       Fig.1 Spectrum radiative rates of
high emissivity in 1 ~ 15 μm
                                               diverse material
wave range.                                             
       Principle of HM-HRC Tech.

The radiative rate of    1.0   Radiative rate ε

common refractory is
                         0.8                                               Ceramic fibre
0.6 ~0.8 under room                                                       Common refractory liner
temperature and                                                           Higher radiative rate coating 1#
decreases obviously as                                                    Higher radiative rate coating 2#

the temperature
increase. But the        0.4

radiative rate of high
radiative coating is     0.2

always keeping above     0
                               20                50                1000Temperature1500
                                    The effects of temperature on the radiative rate of materials
          Principle of HM-HRC Tech.

   According to the law of Geerhofu: the
absorption rate ( the black degree ) is equal to
the radiative rate. It means the absorptive ability
is improved when the emissivity of material
surface increased.
Three Application Models of HRC

 Application Mode I: to Use High Absorption and High
       When the HRC is used on the lining of industrial furnaces,
 such as, reheating furnaces for rolling mills and glass furnaces,
 the heat absorption of linings is increased (about 60% of heat
 absorption of objective heated is from the lining radiation) and
 large amount of heat that cannot be transferred through the
 external wall of furnace will change into the heat with 1~5μm
 wave length radiating into the hearth. The heat with 1~5μm
 wave length can be easily absorbed by the objectives heated,
 such as steel billet, so the heat efficiency of furnace can be
Three Application Models of HRC

Application Mode II: to Use the High Absorption

   When the HRC is used on the external wall of boiler pipes,
vertical fire channel and insulation walls of coking chambers in
coke oven, the heat absorption capacity of external wall of
boiler pipes and insulation wall are improved, and so with the
heat dynamics to the water and coking chamber.
  Three Application Models of HRC

Application Mode III: To use the features of high absorption,
high regeneration; high radiation and high heat emission.
The HRC is used on the regenerator, such as surface of
checker brick. Through the forced radiative heat exchange, the
HRC improved the surface temperature of regenerative body,
increased the temperature difference inside and outside of
regenerative body, improved the heat absorption speed and
volume of regenerative body during temperature increasing,
and improved the heat emission speed and volume during
temperature reducing, therefore, the blast temperature is
     Steel industry is a energy intensive industry and iron
making process in BF takes over 60% of the gross energy
consumption in steel company.
  High temperature blast has been used in BF since 1828 in
America. The theoretic and experimental results indicated that
high temperature blast not only plays a specific role in reducing
coke rate, increasing yield and improving the quality of pig iron,
but also increase the pulverized coal injection rate since high
temperature blast improving coal combustion efficiency. That is
to say, higher temperature blast lead to lower energy
consumption and higher yield. So the BF researchers engaged in
improving the blast temperature.

                             Hot Stove of BF
Hot stove is a heat exchanger which can heat
the air up to more than 1200℃ and provide
blast for BF.
                                        Every BF is equipped
                                        with 3~4 hot stoves
                                        with regeneration
                                        (check brick or
                                        regenerative ball) inside
                                        it. Heat the regeneration
                                        by use of gas from BF,
                                        coke oven and converter
                                        furnace which was
                                        generated during the
                                        iron making process.
                                        Then the air to the BF
                                        was heated by the
                                        regeneration thermal
     BF for iron making
                                        storage which makes the
                                        air up to 1000℃.
    The research on improving the blast
temperature of hot stove mainly concentrated on
material qualities of regeneration, construction
design of hot stove, by use of high performance
fuel both domestic and abroad.

     HRC on the regeneration surface of hot stove of
BF is a new technology which improves the blast
temperature of hot stove of BF in iron making, and
reduces the fuel consumption.

Preparation of HRC (“Jie Neng Wang” Nanometer
High Temperature Far-infrared Energy Saving Coating

Blend the ultra fining technology treated powder with
       the prepared high temperature adhesive

                Add few surface active agent

              High-speed mechanical

                         Viscous fluid
            high radiativity energy saving coating
                                    This picture is the TEM
                                (transmission electron
                                microscope) graph of high
                                emissivity material, the particle is
                                25-120nm. The particle is grinded
                                to nanometer grade (maxmium
                                2μm) by use of ultra fining
                                technique which makes the
                                coating infiltrate into the matrix
                                and form the transitional layer

Micro image of coating powder
                                thus to improve the adhesive
The processes for the coating preparation on
the (checker brick) regeneration of hot stove:

Cleaning the checker brick

       Spraying adhesives

         Coating by soaking (2~3 seconds)

      Drying or Solidifying while a stove drying

Technology for improving the adhesive force of coating:

 1. Interface theory,using the pre-treatment technique in
 coating preparation. Pre-treatment adhesive reduced the
 surface tension, improved the adsorptive capacity of matrix.

     2. Ultra fining technique,nanometer coating particles
      infiltrate into the cavity of matrix, form the infiltration
     combination between coating and matrix.

                    Keeping the coating unshed
It could be seen
that there is some
change in color,
which shows the
coating material
has infiltrated into
the brick about 3
mm thickness.

                                               The small coating particles infiltrate
                                               into the matrix, form the coating
                                               gathering area and present black
                                               particle in micro structure. None
                                               chemical reaction with the matrix.

                                                  The thickness of the
                                                 coating is about 0.3 mm

                                                   Infiltrated depth is 3 mm

Micro structure of the checker brick section

    Coating and matrix formed the coating-transition
layer-matrix construction, the formation of transition
layer is due to the coating infiltrate into the matrix
which guaranteed the fine adhesive capability
between coating and matrix.

 The surface of siliceous    The surface of siliceous
brick before coating (×25)   brick after coating (×25)

     Fine surface coating prevent
     the brick to be break
The surface of high-alumina   The surface of high-alumina
 brick before coating (×25)     brick after coating (×25)

             Fine surface coating prevent the
                    brick to be break
The effects of HM-HRC on the physical property
of the refractory

     The effects of the coating on alumina brick

                Volume                Compression    Break           Linear
                          Pore rate
     specimen   Density                 strength    strength       change rate
                (g/cm3)                (MPa)         (MPa)            (%)

                 2.43        25           49          5.8              -1.42

                 2.48        21           64          6.3              -0.62

The effects of HM-HRC on siliceous brick
         Volume                The strength of   The break      Linear
         Density   Pore rate    compression       strength    Change rate
                     (%)          (MPa)            (MPa)      (%)

Withou    1.80     19.88                                          +0.51
   g                                 28           12.23

 With     1.81     19.27                                          +0.33
   g                                 31           12.65
The softening temperature with loading and the
distortion rate contrast between without coating
          and with coating silica brick
          Softening temperature with   High temperature distortion
          loading (0.2MPa, 0.6%), ℃       rate (1430℃×50h), %

Without            1550                        +0.405
 With              >1650                       -0.074

    The nano/micro coating materials infiltrated in the cavity
of the brick surface which decreased the pore rate and high
temperature distortion rate, increased the volume density,
compression strength, break strength and softening
temperature with loading. All these above are good for
prolonging the service life of the brick in hot stove of BF.

  The influence of coating on the heating and cooling
  speed and thermal storage capacity of refractory

             400                   涂
             200                   未涂
                   0   3   6   9   12    15   18   21   24   27

with coating ——high summit temperature,low heat remnant.
Without coating——low summit temperature,more heat remnant.
blue shadow——heat release of refractory with coating during
temperature increasing.
Red shadow——heat release of refractory without coating during
temperature increasing.

The influence of coating on the thermal storage volume and
unit energy saving efficiency of checker brick
  Measuring the influence of coating on the thermal storage volume and unit energy
  saving efficiency of checker brick at medium temperature (800℃) and high
  temperature (1200℃) by use of calorimeter method.
  Calorimeter method means measuring the heat quantity of water by use of calorimeter
  (Q water), the heat quantity of Q specimen is equal to Q water.
                   Fig 4 the energy saving effect of checker brick
                   under different states.
           Water                          Energy saving efficiency %
         quenching                      800℃                                    1200℃
               1                          8.2                                     18.4
               5                          7.8                                     16.7
               10                         8.9                                     17.8
               15                         7.5                                     15.4
Unit energy saving efficiency τ=m      τ=m without coating(Q with coating/m with coating–Q without coating/m without
coating)/Q without coating×100%   Reflect the improvement thermal storage capacity of coating of the matrix.
    The energy saving efficiency of coating at medium
temperature is less than that at high temperature which
indicates that the mechanism of coating improving heat
conduction ability of refractory is mainly concentrated on
improving the absorption and radiation ability of refractory
surface. Trialed by many times of water quenching, there is
no obvious change in the improvement of thermal storage
capacity which indicate that the application effect is basically
tallies between short period and long period application.

Industrial application
      HM-HRC has been used in 88 hot stoves of BF (300~
  3200m3) since the invention of High Radiation Energy
  Saving Coating on checker brick of hot stove in 2004. HM-
  HRC increased the blast temperature for more than 15℃,
  prolonged the air supply time for 10%, decrease the gas
  consumption for more than 7% and the temperature of flue
  gas average decreased for more than 10 %, or integrates all
  the benefits thus improved the condition of hot stove.

Temperature distribution of checker brick in
      1750 m3 BF of Jinan Steel Company

      Without coating——low wave, low thermal storage

       With coating——high wave, high thermal storage

Temperature distribution of the brick in 1750 m3 BF
 (put into production for three years and seven months)

   Without coating                With coating
HM-HRC on checker brick in No.3 Hot Stove of No.6 BF
             in Changzhi Steel Co.

         3# low temperature of exhaust gas
               ( narrow wave summit)

   Temperature distribution of checker brick in 1#
and 2# hot stove with coating and the 3# without
coating of hot stove in 1080 m3 BF built by Shandong
Shiheng Steel Company

                       With coating higher             Without coating
                      temperature blast ,             lower temperature
                      prolonging time blast        blast , short time blast

   With coating
temperature of flue
    gas is lower

  Without coating
temperature of flue
   gas is higher

  BF Hot Stove

   Improvement of thermal efficiency
   ①the noumenon thermal efficiency of hot stove
                Q1'  Q4  Q6'           1768.29  212.24  58.31
 1#furnace: 1                   =                                =81.26%
                  Q  Q4                   2199.00  212.24

 3#furnace:1  Q1  Q4  Q6 = 1665.57  212.24  54.67 =76.03%
                '         '
                 Q  Q4         2195.53  212.24
   ②thermal efficiency of hot stove
                 Q1'  Q4         1768.29  212.24
1#furnace:  2   Q  Q4  100 = 2199.00  212.24           =78.32%

              Q1'  Q4                    1665.57  212.24
3#furnace:2 
                       100         =                       =73.28%
               Q  Q4                    2195.53  212.24

                                             BF Hot Stove
1 The blast temperature average of hot stove with coating is 25℃ higher
than that without coating, the flue gas temperature average with
coating is 13 ℃ less than the without coating. Reduce the energy
consumption for 3%.
2 The gas combustion is more fully in the hot stove with coating which
reduces the combustible components in flue gas, the heat loss of
incomplete combustion reduced from 1.7% to 0.12%。
3 The thermal efficiency of hot stove with coating is 5% higher than
that without coating and the energy saving effect is obviously stable.

                              BF Hot Stove
      HM-HRC have been used in 88 hot stoves
序号   施工日 期                         应用单 位                               炉 型
1    2004.03   Laiwu Steel Co.             2#1880M3 BF2 #Hot Stove
2    2005.02   Jinan Steel Co.             2#1750M3 BF2 #Hot Stove and 2#、3#Vault
3    2005.04   Shandong Tube Casting Co.   2#350M3 BF3 Hot Stoves
4    2005.05   Jinan Steel Co.             3#1750M3 BF3 Hot Stoves
5    2005.07   Laiwu Steel Co.             1#1080M3BF2#、3#Hot Stoves
6    2005.09   Laiwu Steel Co.             2#1080 M3BF3 Hot Stoves
7    2005.10   Laiwu Steel Co.             2#380 M3BF3 Hot Stoves
8    2005.11   Yongfeng Steel Co.          1#、2#450 M3 BF 6 Hot Stoves Vault
9    2005.12   Handang Steel Co.           3#300 M3BF3# Hot Stove
10   2006.04   Laiwu Steel Co.             2#750M3BF3#Hot Stoves
11   2006.04   Jinan Steel Co.             1#350M3BF2#、3# Hot Stoves
12   2006.05   Qingdao Steel Co.           1#380 M3BF3 Hot Stoves
13   2006.07   Yongfeng Steel Co.          1080M3 BF2# Hot Stove
14   2006.08   Handang Steel Co.           3#300 M3 BF2# Hot Stove
15   2006.08   Handang Steel Co.           5#2000 M3 BF2# Hot Stove
16   2006.08   Tonghua Steel Co.           5#350M3 BF3# Hot Stove
17   2006.12   Handang Steel Co.           1#300 M3 BF2# Hot Stove

18   2006.12   Tonghua Steel Co.           3#350M3 B8# Hot Stove
19   2007.01   Changzhi Steel Co.          6#350M3 BF3# Hot Stove
18   2006.12   Tonghua Steel Co.           3#350M3 B8# Hot Stove
19   2007.01   Changzhi Steel Co.          6#350M3 BF3# Hot Stove
20   2007.05   Ji Nan Steel Co.                 2#350M3 BF2# ,3#Hot Stoves
21   2007.05   Han dang Steel Co.               2#380M3 BF7# Hot Stove
22   2007.05   Shi Heng Steel Co.               1080M3 BF1#,2# Hot Stove
23   2007.05   Wei fang Steel Co.               4#1300M3 BF 3 Hot Stoves
24   2007.06   Tong hua Steel Co.               2560M3 BF 3 Hot Stoves
25   2007.07   Handan Steel Co.                 6#380M3 BF 1#Hot Stove
26   2007.08   Handan Steel Co.(Hanbao)         3200M3 BF 3 Hot Stoves
27   2007.09   Xuan hua Steel Co.               2500M3 BF 1 Hot Stove
28   2007.09   Tong hua Steel Co.               1#、2#350 M3 BF 4 Hot Stoves
29   2007.10   Anyang Steel Co.                 6#350M3 BF 4# Hot Stove
30   2007.10   Chang zhi Steel Co               6#350M3 BF 2# Hot Stove
31   2008.03   Shandong Fulun Steel Ld          1#1350M3BF 1#、2# Hot Stove
32   2008.03   Han dan Steel Co.(Hanbao)        3200M3 BF 3 Hot Stoves
33   2008.04   Tonghua Steel Co.                4# BF 3# Hot Stove
34   2008.05   Qingdao Steel Co                 3# BF 3 Hot Stoves
35   2008.05   Anshan Steel Co                  N5#2580M3 BF 3 Hot Stoves
36   2008.05   Henan Hanyang        Steel Co.   750m3Hot Stoves Vault
37   2008.07   Chang zhi Steel Co               1080M3 BF13 Hot Stove
38   2008.07   Tianjin Steel Co                 2800m3 BF 3 Hot Stoves
39   2008.08   Handan Steel Co.                 3200M3 2Hot Stove
40   2008.09   Chang zhi Steel Co               6#400M3 2#Hot Stove

41   2008.09   Chang zhi Steel Co               3#3500 M3 3Hot Stove

42   2009.01   Lianfeng Steel Co                2#450 M3 2Hot Stove

  “High Radiative Coating Technology” has been listed
in science and technology sustained technology of Science
and Technology Ministry- System Technics Technology
on Super-large-sized Blast Furnace.
  This technology obtained third prize of 2008 National
Metallurgy Science and Technology Award, first prize of
National Association of Industry and Commerce Science
and Technology Progress Award, first prize of Jinan Science
and Technology Innovation Award.
      High radiative coating on hot stove of BF has passed the
authentication of the Expert Committee in which Mr. Shi
Chang-Xu, a senior academician, is in charge of it.

Authentication results: a new inventive technology which
integrates metallurgy material and chemical to one subject, it is
a breakthrough in iron making and energy saving technology
which makes the technology keep the first level in the world, it
deserves highly generalization in the application on hot stove of

  Property right of innovation

    4 Chinese patents have been obtained in the preparation
method , construction technique and regenerator with coating.
The patents application in the US, Japan, Germany, Russia,
Korea and India are undergoing. The US, Japan and Germany
have already officially announced.

     Nanometer High Radiative Coating on the
regeneration of hot stove is a new technology with low
investment and without operation cost which can increase
yield and reduce energy consumption. One time
investment, takes back within half a year, benefits for 30
years. This technology opened a simple and convenient
way for further improving the blast temperature of hot
stove of BF, and has broad prospect of application.


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