Blast Furnace – Cast House & Slag Handling
Stronger protection. Zero interruptions.
Zone Introduction
Blast Furnace Cast House handles molten hot metal and slag flowing at 1400–1500°C.
This zone is extremely critical for safety and continuous ironmaking.
Molten slag is highly abrasive and chemically aggressive — leading to severe equipment deterioration.
Any leakage → Catastrophic safety incident + furnace emergency shutdown.
Process Description
During tapping, molten iron and slag exit the taphole and flow across runners.
Slag is separated and directed into slag pits or granulation units.
Wear mechanisms involved:
- Molten slag particles → High-temp abrasion
- Reactive oxides → Chemical corrosion of steel
- Flow turbulence at bends → Localized erosion
- Thermal cycling between taps → Fatigue cracking
- Accidental skulls → Impact shock loads
These mechanisms rapidly thin metal plates and distort flow channels, threatening containment integrity.
Continuous tapping cycles accelerate fatigue → sudden breakthrough failures can occur without warning.
| Application | Problem Observed | Artha Expertise / Solution |
|---|---|---|
| Bell-less top / Charging system | Severe abrasion due to coke and sinter impact | High chromium Carbide wear-resistant liners for extended service life |
| Bell hopper & distribution chute | High impact and sliding abrasion | High chromium Carbide plates for high-impact and abrasion resistance |
| Stock house chutes | Continuous wear from raw material movement | High-hardness High chromium Carbide liners to reduce maintenance |
| Furnace throat area | Extreme temperature and abrasive burden | High-temperature resistant High chromium Carbide liners |
| Burden distributor | Rapid wear due to material flow and heat | High chromium Carbide wear plates with enhanced thermal resistance |
| Skirt plates | Erosion caused by falling burden material | High chromium Carbide wear liners to increase service life |
| Dust catcher & downcomer | High-velocity dust erosion | High chromium Carbide abrasion-resistant liners |
| Hot blast stove ducts | High temperature and thermal cycling | High chromium Carbide high-temperature resistant plates |
| Cast house runners | Severe wear due to molten metal and slag | Special High chromium Carbide wear-resistant plates for extreme conditions |
| Slag runner & troughs | Rapid erosion and thermal shock | High chromium Carbide wear liners with high thermal stability |
| Mud gun & taphole area | Intense heat and abrasion | High chromium Carbide wear plates for extended operational life |
| Gas cleaning plant ducts | Erosion from hot dust-laden gases | High chromium Carbide plates for erosion resistance |
Areas of Wear & Root Causes
Slag runners & troughs → Hot abrasion + corrosion
Runner junctions → Turbulent flow → Heavy erosion
Slag launders → Impact & temperature variation
Slag runner covers → Oxidation due to hot gases
Performance Loss & Downtime Impact
Runner collapse or leaks → Extreme safety hazard
Emergency maintenance → Production downtime
Poor slag handling → Metal loss & yield reduction
Costly refractory replacement & labor repairs
Recommended Products & Benefits
- Resistant to slag attack and thermal shock
- Maintains structural strength during tapping cycles
- Provides impact + abrasion protection in slag pathways
- Prevents distortion and breakthrough