P S Anand Prakash

Mr Prakash worked for a Boiler manufacturing company as Design Assistant in 1991 & observed a need to improve combustion side workability. He then conducted research on the combustion reaction for over 25 years covering oxidation & redox reaction environments & developed chemical interference agents to selectively fail unwanted reactions.

Topic: Chemical reducing coke rates by 30-50 kgs per THM in blast furnace

Abstract:

1) Acticast chemical innovated by us, induces consistent conditions to chemically fail SLR & DRR, in the BF, raise 30% thermal conductivity within the Ore / Sinter charges, resulting in lower coke rates by Min. 30 to 50 Kg / THM & 7 to 12% higher production.

In depth research of over 15 years covering all aspects of reaction environments in the BF, conditions for success & failure of any reaction, reaction efficiency / inefficiency, root cause analysis for SLR, DRR & solutions that could be offered.

2) Contrary to the general understanding prevailing in the BF, all CO2 does not completely react with C at the Tuyere, some portion remains Unreacted (no reaction is ever 100% efficient).

This Unreacted CO2 enters the Bosh over heats some FeO to higher than successful CO reacting temperature, failing the reaction, creating compulsory conditions for DRR, later enters the Thermal Reserve Zone, causing SLR.

Acticast through its unique coke lattice deactivation, causes SLR failure, in a steady manner, increases coke descent to the Tuyere, lowers Unreacted CO2, thereby even lower DRR.

It is a known fact that both SLR, DRR reactions contribute to 25 to 35% extra C consumption / THM.

3) Acticast chemical tested in laboratory conditions, with addition of 0.03% to 0.05% coke volume, suppressed C + O2 reaction itself at every temperature gradient right from 500 deg C to 1200 deg C, which is 4 times more aggressive reaction than the CO2 + C reaction.

In the BF, higher coke volume descends to Tuyere level with SLR failure, which lowers Unreacted CO2 as extra coke to react is available, lowering DRR in a loop pattern, finally lowering the coke rates by Min. 30 to 50 Kg / THM

4) The results of coke lacing with Acticast chemical is lower DRR, lower SLR, lower heat requirement, lower CO2 emissions, higher CO utilization, lower coke / carbon rates / THM.

The significance of the research is identifying Unreacted CO2 to be the root cause for DRR & SLR & developing chemical methodology to resolve it.

5) In current scenario, most BF’s operate with Coke, Coal combination, have gap greater than 100 Kg / THM between theoretical / stochiometric vs operational requirements due to SLR, DRR, whose gap can be narrowed with Acticast application