Copyright by the Department of Materials Science & Engineering. Department of Materials Science & Engineering. Proceedings of the Symposium on "The -

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1 THE - TAPHOLE THE BLAST FURNACE LIFELINE: DESIGN/MAINTENANCE/OPERATING PRACTICES Edited by G.A. Irons Dofasco Professor of Ferrous Metallurgy Director, Steel Research Centre Department of Materials Science & Engineering McMaster University Hamilton, Ontario, Canada L8S 4L7 Proceedings of the Symposium on "The - Taphole The Blast Furnace Lifeline: Design/Maintenance/Operating Practices" organized by the Department of Materials Science & Engineering and held at the Sheraton Hamilton Hotel Hamilton, Ontario, Canada, May 1-3,2001 Copyright by the Department of Materials Science & Engineering McMaster University, Hamilton, Ontario, Canada Printed in Canada at McMaster University

2 CONTENTS KEYNOTE ADDRESS: THE TAPHOLE: THE HEART OF THE BLAST FURNACE 1 Koos vanlaar, Consultant SESSION 1: TAPHOLE DESIGN TAPHOLE DESIGN AND CASTHOUSE PRACTICE ON THE HIGH EFFICIENCY BLAST FURNACES AT RAUTARUUKKI STEEL, RAAHE 22 T. Karjalahti and J. Swanljung, Rautaruukki Steel Discussion 35 OPTIMIZATION OF TAPHOLE CONSTRUCTION, MAINTENANCE, AND CASTING PRACTICE FOR HIGH PRODUCTIVITY, HIGH RELIABILITY, AND LONG CAMPAIGN LIFE 37 Craig Steigauf and Larry Storm, Bethlehem Steel Corp. Discussion 46 NEW IMPROVEMENTS OF THE TAPHOLE AREA AT THYSSENKRUPP STAHL 48 Thomas Ballewski, Michael Peters, Peter Riither and Peter SchmOle, ThyssenKrupp Stahl Discussion 67 TAPHOLES OPERATING PRACTICES AT SOLLAC-MEDITERRANEE FOS PLANT 68 Christian Cassini, Sollac-Mediterranee/Usinor Group Discussion 80 LIQUID FLOW ANALYSIS IN BLAST FURNACE HEARTH CONSIDERING TAPHOLE LOCATION 83 Akihiko Shinotake, Morimasa Ichida, Hajime Ootsuka, Yasushi Kurita, and Osamu Anzai, Nippon Steel Corp. Discussion 102 GENERAL DISCUSSION 104 iii

3 SESSION 2: OPERATING PRACTICE 1 TAPHOLE EXPERIENCE AT BF6 AND BF7 OF CORUS STRIP PRODUCTS IJMUIDEN 107 Jan de Pagter and Ron Molenaar, Corus Strip Products Umuiden Discussion 126 TAPHOLE DESIGN, CASTING EQUIPMENT, AND OPERATING PRACTICES AT DOFASCO 128 A. Petruccelli, D.H. Pomeroy, R. Chaykowski and F. van Laar, Dofasco Inc. Discussion 148 Short Presentation: AN INSIGHT INTO FLOW BEHAVIOUR OF BLAST FURNACE TAPHOLE STREAMS 149 Q. He1, P. Zulli2, F. Tanzil3, B. Lee3 and G. Evans4 1 formerly BHP Research, now Dept. of Chem. Eng., University of Newcastle 2 BHP Steel Research Laboratories, Port Kembla 3 4 Ironmaking Dept., Flat Products Division, BHP Steel, Port Kembla Dept. of Chem. Eng., University of Newcastle Paper presented by Bob Nightingale ofbhp Steel IMPROVEMENT IN TAPHOLE LIFE AND CASTING PERFORMANCE AT ISPAT INLAND'S NO. 7 BF 156 Brian Black and Jim Bobek, Ispat Inland Inc. Discussion 177 TAPPING PRACTICE AT VOEST ALPINE STAHL LINZ 178 G. Brunnbauer, J. Mauhart, A. Ferstl, N. Nogratnig and B. Rummer, Voest-Alpine Stahl GmbH Discussion 187 GENERAL DISCUSSION 188 iv

4 SESSION 3: OPERATING PRACTICE II THE APPLICATION OF NOVEL TECHNIQUES AND NEW SENSORS TO TAPHOLE MANAGEMENT PRACTICE AT PORT KEMBLA NO. 6 BLAST FURNACE 193 F.W.B.U. Tanzil, RJ. Nightingale, R.C. Lee, J.P. Dunning and J. Ratter, BHP Steel Paperpresented by Nick Di Giorgio ofbhp Steel Discussion 208 TAPHOLE DESIGN AND EXPERIENCE 211 Rainer Altland and Georg Grabietz, Htittenwerke Krupp-Mannesmann and Jtirgen Pethke, Salzgitter Stahl AG Discussion 231 TAPHOLE MANAGEMENT PRACTICES AT LAKE ERIE STEEL 233 Lloyd S. Estrabillo, Lake Erie Steel Company Discussion 242 THE TAPHOLE: A UNIQUE SYSTEM 243 Jason W. Entwistle, US Steel Discussion 259 Short Presentation: PROGRAM TO OPTIMIZE TAPPING OPERATION AT #7 BLAST FURNACE, PRIMARY PRODUCTION 260 Roxie Graystone, Algoma Steel Inc. Discussion 266 GENERAL DISCUSSION 267 v

5 SESSION 4: REPAIRS EMERGENCY TAPHOLE REPAIR AT NO. 4 BLAST FURNACE AT STELCO HILTON WORKS 273 Bruce Edwards and Steve Hutchinson, Stelco Inc. Discussion 291 DAMAGE TO TAPHOLE AND SIDEWALLS OF PORT KEMBLA NO. 5 BLAST FURNACE - CAUSES AND REMEDIES 294 R.J. Nightingale and BJ. Rooney, BHP Steel Discussion 308 REPLACEMENT OF THE SOUTH IRON NOTCH AT LAKE ERIE STEEL'S BLAST FURNACE 311 Jack E. DiCosimo and M. McGahey, Lake Erie Steel Company Discussion 321 DEVELOPMENTS IN TAPHOLE DESIGN, TAPPING METHODS AND REFRACTORY REPAIR OVER THE LAST TWENTY YEARS AT SSAB OXELOSUND 322 Per Ostlund, SSAB OxelSsund AB GENERAL DISCUSSION 341 OPEN FORUM DISCUSSION 343 CLOSING REMARKS 353 LIST OFREGISTRANTS 355 GROUP PHOTOGRAPH vi