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TITLE:

BLOWING IN

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STANDARD OPERATING PROCEDURES FOR BF BLOWING-IN

CONTENTS
SR.N
O

DESCRIPTION

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Introduction

Description of activities

Personal hazards

13

Risks to environment and plant

13

Safety requirement - Training, isolations, PPE, Special equipment

13

Emergency preparedness

14

Safety Equipment required

14

Pre-conditions for Blowing-in Operation

14

Sequential description of activities

15

10

Completion checks

15

11

Important telephone nos.

15

12

List of documents to be maintained

15

13

Monitoring the data - Frequency and corrective actions to be taken.

16

14

Engineering Change notes

16

15

Training records of the employees

16

16

Calibration records

16

17

Documents would be reviewed and authorization

16

1) Introduction :
Blow-in of a blast furnace is a special blast furnace situation.

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In normal operational situations (after a reline or new blast furnace), a blast furnace is blown in with all
tuyeres. It means that the liquid connection between tap-hole and furnace has to be established rapidly,
since iron will be produced as soon as burden containing material starts to melt, i.e. reaches temperatures of
1100C and higher.
So, the main areas of interest for a blast furnace operator are:
Heating up the hearth and rapidly establishing a good liquid drainage from tuyere to Tap hole
Making good, liquid slag
Heating up the furnace above tuyere level and establishing a proper melting zone and gas flow
control
Rapid increase of productivity while reaching also good hot metal quality properties
Blowing in a furnace from new can be considered in two phases:
Phase 1: Heating-up the hearth
Phase 2: Start reduction processes and iron production

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Mr.

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Mr.

Mr.

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2)

Description of activities:

A.

Drying the furnace

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BLOWING IN

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It is desirable to dry the lining brick work before filling the furnace.
The hot blast will be used for drying of the Furnace as per the schedule.
In order to carry the heat into the hearth, extension pipes can be fitted to some of the tuyeres to
lead the hot blast into the Furnace bottom. It is advisable to place steel plate under the outlet of the
pipes to prevent erosion or local overheating of the hearth brickwork.
Prior to the drying blast being put on, the hearth should be swept clear of any debris.
Water should be turned on to all Tuyeres & Tuyere coolers, Staves cooling and check made that
the water is flowing through the hot blast valves and seats before blast is put into the furnace.
The Furnace bleeders should be shut and checked to be air-tight.
Furnace top should be sealed and a purge point at the dust catcher is left open. Sufficient hot blast
is blown through the tuyeres in order to create a positive pressure at the open points.
Blast temperature should not exceed for 100deg centigrade during the drying out in order to protect
carbon brick-work.
At least 2 stoves should have the heated up prior to this time to provide this blast temperature.
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TITLE:

BLOWING IN

In order to monitor the progress of drying out, thermocouples can be fitted via the tap hole into the
furnace hearth at varying depths, in to the stack brick work & at throat area.
Drying out should commence with the use of cold blast and the temperature should be gradually
increased to a maximum of 4000C over a period of 24 48 hours.
Blast volume at a temperature of 4000C should be maintained for at least 72 hours. This is the
minimum recommended period at this temperature required for drying out.
When drying is complete the blast temperature is progressively decrease to cold blast over a period
of 48 hours. This cools the furnaces prior to the removal of the drying pipes, installation of tap hole,
cooling members, tuyeres etc in readiness for filling.
The drying regime would be as follows
HBT Range in
o

upto 150

Heating rate in
o

C/hr
15

Soaking at 150
150-200

12.5

Soaking at 200
200-300

12.5

Soaking at 300
300-400

20

Soaking at 400
Total

Duration in hrs

HB Pressure in
Kg/cm2

0.1

24

0.1

0.1

12

0.1

0.1

12

0.1

0.1

23

0.2

96 Hrs (4 Days)

During drying the top temperature shall not exceed 300 oC. The same shall be controlled by wind
flow and if necessary HBT.

Hearth temperature measured through tap hole shall be at least 300oC

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In case of power failure water to cooling members shall be ensured from the Emergency overhead
tank or Fire Water line.

Checking of leakages can be done at 0.3 Kg/cm2 pressure.

After the completion of drying furnace will be cooled by blowing cold blast through the mixer line to
the extent possible. Thereafter furnace will be cooled by natural draught till 70-80 oC. If required 2-3
small fans/blowers will be arranged at tuyere openings to increase the cooling rate.

Bleeder valves of furnace, relief valve, equalization valve. Back draft valve, tuyere peephole
flanges, tap hole, top manholes etc. will be opened for natural draught cooling.

L- pipe 120mm Dia

Length appx. 6.5 mtrs

Taphole pipe 80mm dia * 4.5mtrs

200 mm
Corrugated

Blank Plate

Hearth Bottom

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B. Filling the Furnace

Precautions to be taken before entering into the furnace:-

Ensure that the furnace is sufficiently cooled for men to enter the furnace hearth.
Specified tuyeres and Tuyere coolers will need to remove to allow entry into the furnace.
The cold blast, stove gas, crude gas systems and other service must be positively isolated from the blast
furnace.

A bleeder must be wedged open along with Tuyere stock doors to ensure adequate ventilation prior to
men entering.

The charging system must be electrically isolated and LSV & LMG must be clamped to the closed
position; the stock rod should be isolated and then clamped or removed; all open apertures at the furnace
top must be blanked.

All purging mediums must be positively isolated.

All furnace probes must be isolated and valves into the furnace closed.
Open the Back draft valve.
Insert a 6 inch diameter pipe through the tap hole. The pipe should be in two sections joined together in
the tap hole by a loosely fitting sleeve. The section inside the furnace should reach between quarters and
halfway across the furnace. The section outside should be about 1.5m long (4-6ft). Some remote means
of removing this section of the pipe should be provided to allow the clay gun to stop the tap hole. Ram
clay into the space between the tap hole brickwork and the pipe.

Fill the hearth of the furnace with large wood up to 1meter above the Tuyere level.
Lay kindling wood in front of each Tuyere inside the furnace. Stand old railway sleepers against the bosh
walls to protect the tuyeres.

Carbonaceous tap hole clay can be rammed around tuyeres and tuyeres coolers for additional protection.
Fit any tuyeres or coolers which have been withdrawn while filling the hearth. All personnel should be
warned against fire danger or light clay plugs should be used at the tuyeres stock doors to prevent
accidental ignition. Sufficient lime stone should be included into the flux, the coke ash; magnesium
limestone is useful for this purpose. During the initial stages of this operation all weighing mechanism
should be carefully checked for accuracy. The importance of monitoring this check weighing cannot be
over emphasized and special arrangements must be made to do this.

After wood filling, 50% of working volume should be filled with Coke and flux.
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Charge the blowing in burden starting initially with a very low ore to coke ratio, this ratio should be
increased gradually as the furnace is filled. The exact ore to coke ratios required will depend on the
quality of coke and iron bearing material. Only experience can show what these ratios should be at the
various stages. The aim should be achieve uniform ignition in addition to producing large volume of hot
slag to carry heat into the furnace hearth.

As a guide to operators, plants normally start charging the burden above coke blank that an ore to coke
ratio of 25% of normal operating level increasing to 50/60 % by the time the furnace is filed to a stock
level of 2.0 meters. This progression should ensure a control of top gas temperature during the initial
stages of blowing in.

The automatic stock rod should be introduced into the electrical charging sequence when by calculation
the furnace is approximately half full. This will ensure that the stock rods are working correctly and that
there will be no possibility of jamming the BLT material hopper.

The burden to be charged after the furnace has been light should also be calculated and made available
to the appropriate person. The ore/coke ratio of this burden should be increased by stages, eventually
reaching the normal burden. The time which is necessary to achieve to the normal ore/coke ratio can only
be determined by experience and by the furnace condition during the blowing in.

C. General Preparation
Convey a meeting of all persons directly concerned and have the records of previous blow-ins available.
A person should be nominated to control the operation. The meeting should prepare a plan of action, set
up the organization, agree a program and set up a control for monitoring purposes. Arrangement should
be made to keep a record of the detail of the work carried out.
Potential hazard exists from gas around cast house working platform during the blow-in; arrangements
must be made to have resuscitators and breathing apparatus available along with trained personnel.
All other works departments and contractors indirectly or directly involved with blast furnace should be
informed of the impending blow-in and the safety arrangements associated with it.
Check that the stove and hot blast system are correctly heated up to the level of the required blast
temperature for blowing.
Check that the gas cleaning plant is ready.
Ensure the correct instructions have been given to the followings:

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Furnace supervisory staff: The complete detail program should be fully explained before blow-in
date. The safety instruction should be understood.

The issued charging instructions should cover the first 48 hrs blowing.

The instructions should include information about sequence the stove charging, temperature
requirements and safety precautions.

Furnace shift crew. These instructions should include program of events safety precautions. Cooling
system personnel (as for the furnace crew). Gas cleaning plant personnel and dust catcher operator.

Detailed program of blowing requirements during blow in should be given to blower operator.

Other departments personnel involved in blow-in. precise instructions as to their duties and safety
instructions should be given.

If the furnace has been isolated from the crude gas main by means of blank plates in addition to
normal isolation valves, then this plate should be removed prior to lighting the furnace. Check the
goggle valve isolating the furnace is closed before removal of plate.

Ensure that the dust catcher bottom is sealed without relaying only on the valve. In preference sand
should be used.

Check that all inspection covers mains, gas cleaning plant etc. are closed.
Check all instruments, blower signaling and all other communication equipments.
During this stage a final check should be made on the operation of following items.

A comprehensive list to be made of the position of all operational valves.

Charging equipments including BLT gates & valves, rotating chute, relief valves, primary &
secondary equalizing valves, stock rod, sinter and coke screens etc.
Furnace bleeders and purge, equalizing, relief, septum valves.
Stove including gas valves cold and hot blast valves, waste gas valves, stove pressure relief
valves, mixing valves and snort valve.
The furnace top should be checked for tightness during the drying out of the furnace and
should be rechecked before igniting the furnace.
Steam/Nitrogen purging to the various points.
Cooling water to furnace and stoves.
Under hearth cooling system should be checked.
Check the furnace normal and emergency lighting systems are operating correctly.
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Check the oxygen supply for burning out tap hole is operational.
Check the gas flares for drying troughs and igniting gas are available.
Fill all necessary water seals in the gas system.

Front side equipments should be made now ready.

Check the operation of mud gun, tap hole drill and cast house auxiliaries.
Check that the following materials are available-Mud gun clay, sand, rice husk, coal, oxygen lances,
and wood for trough or front side tools.
Tap hole, trough and slag runner should now be prepared.

D. BLOWING-IN

Two to three hours before blowing in check that the cooling water is fully on the furnace.

Check that the stove valves are closed, and that there is a circulation of water through all water cooled
members.

Open all furnace bleeders and ensure that the BLT gates & valves are closed.

Ensure that the previously opened dust catcher bleeder is open.

Turn purging medium into the cold blast main and start the blower releasing the air to atmosphere through
the snort.

Ensure that all blow pipes are connected.

Clear all personnel from furnace top, stack, and galleries, isolate the lift physically prevents further access
these areas.

Turn purging medium into dirty gas mains, dust catcher and furnace top. Check water seals in gas
cleaning plants. Check that the gas plant is purged ready to receive blast furnace gas.

Ensure that the dirty gas mains, dust catcher and furnace top are thoroughly purged before the furnace is
ignited.

Ensure that the gas issuing from the tap hole will be kept ignited by maintaining fire in the iron runner at
the mouth of the pipe.

All personnel not connected with the operation should be cleared from the site and the furnace area
should be cordoned off.

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When all tuyeres are well ignited, close the Tuyere stock face pieces and put blast on the furnace at the
required volume/pressure/temperature.

As soon as possible ignite any gas leakages around the furnace and ensure that these are ignited.

Analysis should be made of the gas issuing from the furnace bleeders prior to this being put into the
gas system. The analysis should be less than 0.6% oxygen. When this is achieved open furnace
isolation valve and close bleeders, then turn off purging medium.

Continue blowing gently, ensuring that the pipe in the tap hole is kept clear as long as possible. When the
gas is finally extinguished remove the outer section and lightly plug the tap hole.

The time of the first cast can be decided by calculation from knowledge of the material charged since
putting the blast on. When opening the tap hole for the first cast the hole should be burned horizontally.

Continue blowing to the agreed program casting the furnace as appropriate and gradually lowering the
tap hole to its normal position and angle.

Do not open dust catcher until sufficient dust has been deposited to ensure resealing.

F. BLOW-IN BURDENS

The calculations are intended as a guideline for the calculations to be made by ESSAR technologists.
The burden calculation of the client is to be checked with the data in this report and used for blast furnace
operation.

Design Basis
The main design parameter for the burdens is as follows.
Throat diameter
- 7.9 m
Working volume
- 1909 m3
Max. top bin volume
- 50 m3
Volume of hearth
- 427 m3
Coke layer thickness
- 480 mm
Initial burden basicity
- 0.7
Initial HM silicon content for burden calculation - 4%
Slag Al2O3
< 17%
Slag MgO
- 7 to 8
Initial coke rate
- 800 kg/thm
Final total fuel rate
- 550 kg/thm
The blow-in is to be done for all coke operation. PCI will not be available during the blow-in.

Burden and charge details

When the raw material analysis are available the burdens will be calculated based on the following
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plan.
Proposed Blow in burden plan:

Coke
Rate
(Kg/THM)
1
800
2
700
3
625
4
575
5
560
6
550

TITLE:

Slag
Basicity
0.7
0.7
0.75
0.8
0.85
0.85

BLOWING IN

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HM Si%
4
3
2
1.5
1
0.8

Charge Vol.
(%WV)
50%
50%
50%
75%
100%
100%+

It is the aim of the blow in to achieve a low HM silicon (< 1%) and stabilize the fuel rate as soon as
possible. To do so the fuel rate must be quickly decreased. Hot blast moisture injection may also
used during these stages.

In the initial stages of the blow-in the final slag basicity IB2 is held at 0.7. This ensures a slag with a
low liquidus temperature, even if the HM silicon levels are higher than expected.

The slag basicity can only be increased when the HM silicon is at or below the target value used in
the burden calculations.
Thus unlike the coke rate the changing the slag basicity is done on the basis of the hot metal silicon
measurements.
If the slag basicity is increased while the hot metal silicon is still higher than anticipated in the blow in
burdens, higher basicity slag will occur which is harder to drain from the hearth and handle in the
cast house.
If the HM silicon is not at or below the target value used in the burden calculation for the specific
burden the slag basicity will not be increased and the burdens must be modified.

PROTOCOL FOR BLOWING IN OF BLAST FURNACE

1. Before the blowing in Power , Turbo Blower station and Gas safety department
should be informed.
2. Check the readiness of furnace cooling system and emergency backup system.
Check the steam and the
presence of steam in the collector, check the under heart
water cooling, check the nitrogen in the N2 line.
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3. Check the readiness of mechanical & electrical equipments and instruments.

4. Check the readiness of charging system and the presence of blowing in burden
materials.
Control strictly the sequence and weighing of materials being charged. To take the
burden materials for blowing in burden (Iron ore, Sinter, Limestone, Dolomite, Quartz
and Coke) in bunkers in advance. Chemical analysis is to be taken for all raw materials
prior to blowing in burden.
5. Inspect all the gas and air mains of the furnace to ensure the absence of any
extraneous objects.
6. Position of different valves before starting of blowing in burden as follows:
All the manholes in the gas mains, Hot Blast, air mains and Dust catcher - Close.
Furnace bleeder and GCP bleeder valves Open.
All manholes in GCP Close
Goggle after dust catcher Close.
Dust extraction valve Close.
Flap valve of Ventury-1 Full Open.
Equalizing valve Close.
Relief Valve Open.
Hatch door Open.
7. Before starting the charging the furnace ensure the following :
Close all Hot Blast and Cold Blast valves in stoves.
Close Mixer shut off and control valve.
Open snort fully.
8. Two hrs before starting the charging ask TBS to run the blower at slow speed to
receive
blast with snort at open position. Blast pressure in blast main should not be more than
0.4
Kg/cm2. Adjust mixer valve to have positive pressure at the Tuyere stock.
9. Forbid all works connected with fire near the furnace in the cast house
area and at the top in order to avoid self burning of blowing in burden.
Remove all unauthorized persons from vicinity of the furnace.
10. During the process of charging the Chute must be kept at the position mentioned
in Blowing in burden. Gas safety man must be under constant duty on the top to take
samples for CO analysis at the levels where persons can take measurements. All blow
pipes must be fixed and peep hole flanges to be kept open before starting the
charging.
11. After filling the furnace up to the predetermined level close the lower material gate
and lower seal valve.
12. All the stoves to be heated at the temperature of 1200 deg C and kept in Isolation.
13. After completion of charging close the hatch door.

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14. Check the readiness of GCP for receiving gas and ensuring water level has been
maintained in Venturies. Give steam to dust catcher and check its presence through
the respective bleeders.
15. Dust valves of dust catcher should be purged with steam.
16. One hour before blowing in inform TBS to increase the blast up to a pressure of 1.1
to 1.3
Kg/cm2 and volume 2000 to 2200 Nm3/min. Snort will be in open position.
17. Remove all the persons from furnace top, dust catcher, stove dome and
other gas
hazard places. Remove all unauthorized persons from the working platforms
of
stoves.
18. Ensure all the cooling members in cooling system are working properly and
position of
all the valves is as per the protocol. Then complete the following for Blowing in :
Ensure that the all tuyeres is fully open.
Close all the peep hole flanges and ensure presence of blue glass in all
peepholes. The peep holes should be visible.
Open the cold blast pressurization valve of a well heated stove
Open the hot blast of that stove.
Open the cold blast valve of that stove fully.
Close the snort to increase the hot blast pressure to 1.0 to 1.2 Kg/cm2 and
blast temperature should not be less than 800 deg C.
19. With the beginning of coke burning at the tuyere light up fire on main runners in
front of
the tap hole to burn the gas if any.
20. Periodically open the peep holes for blowing and watch them continuously to
ensure they
are clean.
21. Blow the gas to furnace bleeder for at least 30 min and take gas samples for
analysis from
uptake tapings. Till O2 concentration becomes less than 1%.
22. After blowing for 30 minutes open the snort to bring down the blast pressure to 0.3
to 0.4
Kg/cm2.
23. After one hour as per separate protocol charge gas cleaning plant by opening the
goggle
valve after dust catcher.
24. Ensure that Flap valve of Ventury-1should be opened fully. Purge GCP and semi
clean gas line
with steam and nitrogen till oxygen percentage comes below 1. Take samples of gas
from GCP.
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25. When oxygen is less than 1% close steam and nitrogen to dust catcher & semi
clean gas line. Close dust catcher bleeder and GCP bleeders at venturies top.
26. When O2 in BF gas is less than 1%, open the equalizing valve.
27. After BF gas in GCP is completely charged close the furnace bleeders and follow
the procedure to charge the gas network consequently.
28. Charging in the furnace to be continued with blowing in burden maintaining the
given charge level.
29. Blast regime to be established as per the pre determined schedule. To establish
the required blast temperature open the mixer shut off valve fully and control valve
partially.
30. Remove dust from dust catcher after 30 40 hrs of blowing in.
31. All the operations connected with blowing in and after blowing in should be noted
in a log book.
32. All the persons connected to the blowing in operation of the furnace should be
acquainted with instructions and strictly follow the same.
33. Gas safety personnel should be on constant during the blowing in and after that to
take air samples for CO testing in the working platforms around the furnace. Remove
all unauthorized persons from hazards zones.
34. Use burning torch to burn the gas continuously for any leakage of gas around the
furnace, especially at the bottom of furnace.
35. For the first day after blowing in during the stoppage do not take the furnace on
back draught because of the presence of high calorific value gas.

3) Personal hazards - in or around the work:

a)
b)
c)
d)
e)
f)
g)
h)

Burnings due to spillage of hot metal

Gas leakages
Water accumulation in the ladle and nearby area
Fire hazards
Noise pollution
Hazards with Compressed Air/N2, steam, oxygen and Natural Gas.
Material handling hazards.
Skin burning due to direct contact with liquid slag, hot blast, hot water.

4) Risks to environment and plant - Associated with the work:

a) Hot metal overflow due to over filling of ladle
b) Gas leakages.
c) Spillage of hot metal due to puncture of ladle/spout

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d) Fire/explosion.

5) Safety requirement - Training, Isolations, PPE, Special equipment:

a)
b)
c)
d)

First aid training for Gas hazards..

Training for proper movement of ladle/locomotive
Training on usage of fire extinguishers.
Ensure that all operators are wearing helmet with face guard, safety shoes, leather hand gloves,
Aluminium aprons and Safety goggles.
e) Chilled water showers.

6) Emergency preparedness:
.

A)

In case of Mud gun failure

a) Inform to Shift incharge & maintenance crew.
b) Refill the Mud gun with Clay and try again to close the tap hole .
B) Fire Hazards
a) Inform to fire and safety control room and seek for assistance.
b) Inform to Shift in charge and all concern
c) Take following actions to control and mitigate the fire:
Press the emergency push button (if required)
Remove all personnel from the leakage area.
Also please refer the EPP for the fire
e) Prepare fire incident report and send it to fire control room for detail investigation to avoid
such type of fire in future.

7) Safety Equipment Required.

Safety appliances
a)
b)
c)
d)
e)

Safety Helmet
Safety shoes.
Heat resistant hand gloves.
Aluminium apron
Dust mask.

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f)
f)

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Chilled water showers.

First aid box

Responsible person:
1. Shift / Cast House incharge.
2. Mechanical Incharge
3. Electrical in charge.

8)Pre-conditions for Blowing-in:

After the completion of material filling Blast Furnace was ready for Blowing in and at that time the status
of system was as below :
1. Stock house - Ready
2. Charging system - Ready
3. Level indicators - Ready
4. Air, N2 & Steam - Ready
5. Furnace cooling system Ready
6. Gas system - Ready
7. GCP cut off valve - Close
8. Dust extraction valves - Close
9. Blowers - Both running
10. Tuyeres - All open
11. Tap holes - Both open
12. Bleeders - All open
13. Mixer valves - Both open
14. All stoves Heated

9)Sequential description of activities:

Drying the Furnace
Filing the Furnace
Blowing-in
Each of above is described in Sec-2
10)

Completion checks

ISSUED BY :
ISSUED DATE :

APPROVED BY :

BLAST FURNACE

REF NO

STANDARD OPERATING PROCEDURES

OF BLAST FURNACE DEPARTMENT

A positive a++itude

TITLE:

BLOWING IN

REV NO
: 00
AMD NO
: 00
EFF. DATE
:
Page: 17 of 18

It is the aim of the blow in to achieve a low HM silicon (< 1%) and stabilize the fuel rate as soon as
possible.

11)

Important telephone nos.

a) Blast Furnace operation control room - ***********

b) Head of the department contact no - +919879100024
c) Fire and safety control room -2222/6666.
d) Care hospital /Ambulance 5100/6222.
e) Security control room -2300/6040.
Pre-conditions for Blowing-in Operation

12)

List of documents to be maintained - As a backup.

a) Operation/maintenance log book(Blowingin log book)

b) Operation log book (Control Room log book).
c) Shift Manger and Shift In charge log book (Operation, Mechanical, Electrical and
Instrumentation).

13)

Monitoring the data

Periodical observation of all proper Thermocouples readings, pressure gauges and the Gas analysis.

14)

Engineering Change notes - Records to be maintained with proper approvals and formats.

a) All the engineering changes shall be approved on prescribed format from HOD with proper
reasons for changes; P & ID s shall be revised and documented.
b) After changes being made, rewrite the SOPs and revised documents shall be issued to
respective control rooms.

15. Training records of the employees

a) Trainings attended by all executives of the Furnace Management shall be recorded in monthly &
annual dept report.

16. Calibration records For all the measuring instruments

ISSUED BY :
ISSUED DATE :

APPROVED BY :

BLAST FURNACE

REF NO

STANDARD OPERATING PROCEDURES

OF BLAST FURNACE DEPARTMENT

A positive a++itude

TITLE:

BLOWING IN

REV NO
: 00
AMD NO
: 00
EFF. DATE
:
Page: 18 of 18

a) Field instruments monitored regularly (shift wise), replaced or calibrated if any problem is noticed.

17. Documents would be reviewed and authorised person for the change in SOPs.
a) Head of the department / Blast Furnace Operation In charge.
b) SOP Shall be reviewed every 2 years and record shall be maintained.

ISSUED BY :
ISSUED DATE :

APPROVED BY :