2011 0601

School of Metallurgical and Ecological Engineering, University of Science

and Technology Beijing

Thermal balance test report for blast furnace hot stoves

Commission unit: Shougang Jingtang United Iron & Steel Co., Ltd.
Product name: Jie Neng Wang energy-saving coating applied in BF hot stoves
Test item: Comparison of thermal efficiency and gas consumption between 1#
and 2# blast furnace hot stoves

Commission unit (stamp)

Test academy (stamp)

Report date: 2011.06.20

The Thermal Balance Test Report forBF

Hot Stove in Shougang Jingtang United Iron & Steel Co., Ltd

1. Comparison purposes:
The 2# 5500m3 BF hot stove in Shougang Jingtang United Iron & Steel Co., Ltd.
(Jingtang Co. for short) applied the Jie Neng Wang energy-saving coating self-invented
by Shandong Huimin Science & Technology Co., Ltd. This test report focuses on the
comparison of thermal efficiency while supply air temperatures were similar between 2#
5500m3 BF hot stoves with Jie Neng Wang coating and 1# 5500m3 BF hot stoves without
coating. And the energy-saving effect of coating was also investigated in this test.

2. Comparison objects:
2# 5500m3 BF hot stoves (with coating) and 1# 5500m3 BF hot stoves (without coating)
in Jingtang Co.

3. Comparison benchmark
3.1 Test Period
Data is selected based on the similar air supplying temperature, so the selecting time
segments are as follows: for 1# blast furnace, 1st to 31st March 2010; and for 2# blast
furnace , 21st to 31st August 2010. The hot stoves in Jingtang Co. use the operate system of
two burning-two blasting. Specific list is shown in table 3.1.

Table 3.1 The operate system of BF hot stoves

Combustion

Blast Time

Combustion- Blast

Blast- Combustion

Time (min)

(min)

Switch period (min)

Switch period (min)

Blast System 1#

96

120

15

Blast System 2#

84

108

15

3.2 Base temperature

2

Treat the ambient temperature as base temperature, the 1# BF hot stove is 13 and
the 2# BF hot stove is 24.

4. Test contents and data processing

4.1 Test contents and data processing
Using the infrared thermometer to test the heat dissipation of hot stoves in this test and
get the average in the test period. And Jingtang Co. gives other data.
4.1.1 Thermal dissipation parameters of BF hot stove surface
Use the infrared thermometer to test the temperature of furnace surface. It was tested
several times in the test period. The combustion chamber is tested from 5 sections and 6
sections in regeneration chamber. At last, the average value is calculated.
Table 4.1 The temperature data of hot stove
a1# blast furnace hot stove
surface temperature in combustion chamber in BF hot stove
Position

Point 1

Point 2

Average

56.2
65.8
78.0
83.5
62.3

60.1
68.9
82.5
85.6
63.1

58.2
67.4
80.2
84.6
62.7

Section 186.5 m
2
Section 2211.6 m
2
section 3170.4 m
2
Section 4145.1 m
2
Section 5278 m

surface temperature in regeneration chamber in BF hot stove

Position

Point 1

Point 2

Point 3

point 3

Average

Section 1
Section 2
Section 3
Section 4
Section 5
Section 6

42.2
48.8
52.4
56.9
59.7
66.8

43.5
48.3
52.9
57.1
60.3
64.0

44.2
47.5
51.2
56.3
58.9
66.7

44.3
50.2
54.4
60.3
60.9
67.6

43.5
48.7
52.7
57.6
59.9
66.3

Case descriptionevery test point is 90o apart round the section of hot stove .

b2# Blast furnace hot stove

3

Surface temperature in combustion chamber in BF hot stove

Position

Point 1

Point 2

Average

61.3
69.2
81.2
88.6
70.1

59.7
69.3
83.1
86.4
67.2

60.5
69.2
82.1
87.5
68.6

Section 186.5 m
2
Section 2211.6 m
2
Section 3170.4 m
2
Section 4145.1 m
2
Section 5278 m

Surface temperature in regeneration chamber in BF hot stove

Position

Point 1

Point 2

Point 3

Point 4

Average

Section 1
Section 2
Section 3
Section 4
Section 5
Section 6

35.7
40.4
46.9
56.1
60.1
71.3

33.4
37.4
42.7
50.6
55.0
65.3

35.8
39.8
44.9
51.6
56.8
66.0

39.7
44.1
50.7
56.6
61.0
71.2

36.1
40.4
46.3
53.7
58.3
68.4

Case descriptionevery test point is 90o apart round the section of hot stove .

4.1.2 Initial data of thermal diagnosis test

Table 4.2 Initial data of 1# BF hot stove

Gas

Air

Cold blast

Name

Hot blast
temp

Flue gas
temp

Temp

Flow

Temp

Flow

Temp

Flow

Unit

Nm3/h

Nm3/h

Nm3/min

Numerical
value

196

187705

560

151107

199

4315

1304

330

Cooling water
Name

Hot blast tube

Stove surface area

water temp

Leaving
water
temp

Surface
area

Surface
temp

Regeneration
chamber

Combustion
chamber

Entering
Flow

Ambient
temp

Unit

Nm3/h

m2

m2

m2

Numerical
value

1208

37.0

38.1

754.5

98

726

891.6

13

Table 4.3 Initial data of 2# BF hot stove

Gas

Air

Cold blast

Name

Hot blast
temp

Flue gas
temp

Temp

Flow

Temp

Flow

Temp

Flow

Unit

Nm3/h

Nm3/h

Nm3/min

Numerical
value

186

174822

560

142137

227

4308

1303

317

Cooling water
Name

Hot blast tube

Stove surface area

water temp

Leaving
water
temp

Surface
area

Surface
temp

Regeneratio
n chamber

Combustion
chamber

Entering
Flow

Ambient
temp

Unit

Nm3/h

m2

m2

m2

Numerical
value

1099

39.3

41.2

754.5

105

726

891.6

24

4.1.3 Gas parameters

1Gas components
The fuel of hot stove is blast furnace gas. The dry gas components are as follows:
Table 4.4 Dry gas components (%)
Components

CO2

CO

CH4

H2

N2

1# Gas content (%)

24.27

22.19

0.01

3.86

49.90

2# Gas content (%)

21.71

23.22

0.03

3.02

52.02

The estimated water content in gas is: 1# water content in gas is 0.6% (about 4.85
g/m3); 2# water content is 0.3% (about 2.45 g/m3). The conversed wet gas components
are shown in Tablet 4.5.
5

Table 4.5 Wet gas components

components

CO2

CO

CH4

H2

N2

1# Gas content%

24.12

22.06

0.01

3.84

49.37

2# Gas content%

21.64

23.15

0.03

3.01

51.86

2Low calorific value of fuel

To calculate the low calorific value of fuel base on the thermal effect of the
combustible gas components in 1% gas volume. In this test, the combustible components
include CO, CH4 and H2

QDW 126.36CO 107.85H 2 358.81CH 4 4.1

Table 4.6 Thermal effect of combustible gas components of 1% volume in 1 m3 gas fuel
Combustible
components

CO

H2

CH4

C2H4

C2H6

C3H8

C4H10

H 2S

Thermal effect
kJ

126.36

107.85

358.81

594.4

634.55

931.81

1227.74

233.66

According to the above thermal effect of combustible components, the low calorific
value of fuel is calculated as follows:
1# gas QDW 126.36CO 107.85H 2 358.81CH 4
126.3622.06 + 107.853.84 + 358.810.01
3205.23 kJ/m3

2# gas QDW 126.36CO 107.85H 2 358.81CH 4

126.3623.15 + 107.853.01 + 358.810.03
3260.63 kJ/m3

4.1.4 Flue gas parameters

1The generated amount of flue gas
6

The actual generated amount of flue gas is got by the following formula:
Vns Vo [ (1 0.00124 g k ) 1] Lgo

4.2

1. Theoretical amount of dry air Lgo

Lgo 0.0238(H s2 COs ) 0.0952CH s4

4.3

Table 4.7 Theoretical amount of dry air Lo

1# BF hot stove

2# BF hot stove

0.6174

0.6255

Theoretical amount of dry air

Lgo

2. Theoretical generated amount of flue gas Vo

Vo 0.01 (COs 3CH s4 CO s2 H s2 N s2 H 2 Os ) 0.79Lgo 4.4

Table 4.8 Theoretical generated amount of flue gas Vo

1# BF hot stove

2# BF hot stove

1.4879

1.4946

Theoretical generated
amount of flue gas Vo

3. Moisture content in dry air g k

According to the ambient dew temperature, when test the dew temperature of 1#
furnace is 6 and the dew temp of 2# furnace is 13.
gk

is shown in Table 4.9.

Table 4.9 Moisture content in dry air g k

1# BF hot stove6

2# BF hot stove13

7.48

12.1

Moisture content in dry air

g k (g/m3)

4. Air ratio
Table 4.10 Air ratio

Air ratio

1# BF hot stove

2# BF hot stove

1.30

1.30

By the above four steps and formulas (4.2) it can be obtained that:
s

Table 4.11 The actual generated amount of flue gas Vn

1# BF hot stove

2# BF hot stove

1.6806

1.6944

The actual generated amount

s

of flue gas Vn

2Flue gas components

Oxygen and CO contents in the flue gas are provided by the Jingtang Co. and other
data is calculated according to the burning reaction of air and gas. The calculation results
are shown in Table 4.12.
Table 4.12 Average value of flue gas components%
Item

O2

CO2

N2

CO

H2O

1# hot stove flue gas

2.28

27.48

67.59

0.0011

2.65

2# hot stove flue gas

2.26

26.45

69.27

0.03

1.99

4.2 Heat input and output calculation

Heat input items

1Chemical heat of fuel Q1

Q1 B QDW

(4.5)

In equation (4.5): QDW is the low heating value of gas. Gas consumption B is obtained by
the ratio of gas volume and air volume of a hot stove in the test cycle.

Vm r
Vf f

4.6

In equation (4.6): r and f is the time of combustion and blast period of a hot stove;

Vm is the average gas flow rate of a hot stove;

V f is the actual blast flow rate of a hot stove, V f B f V f 1 (1 l f ) (*)

In equation (*): V f 1 is the average flow rate of cold blast measured at the cold blast test
point;

B f is the comprehensive correction coefficient of air volume of the tested hot

stove, here takes 1;
l f is the air leakage of the tested hot stove system, here takes 0.

Gas consumption B obtained by calculation is shown in table 4.13:

Table 4.13 Gas consumption B

Gas consumption B
Nm3/ Nm3

1# BF hot stove

2# BF hot stove

0.58

0.53

According to formula (4.5), we obtain the fuel chemical heat Q1 which is shown in table
4.14:

Table 4.14 Chemical heat Q1

Chemical heat Q1 kJ/ m3

1# BF hot stove

2# BF hot stove

1859.03

1728.13

2Fuel physical heat Q2 :

Q2 B(cm tm cmc tc )

(4.7)

In the equation: t m is the average gas temperature;

tc is the average ambient temperature;

cm and cmc are the average specific heat of gas during 0~ t m and tc respectively.
Table 4.15 Fuel physical heat Q2
9

1# BF hot stove

2# BF hot stove

147.70

125.56

Fuel physical heat Q2

kJ/ m3

3Physical heat of air Q3 :

Q3 B Lso (ck tk cke te )

(4.8)

In the above: Lso Lgo (1 0.00124 gk )

(**)

In the equation: Lgo is the theoretical amount of dry air;

g k is the moisture content of dry air;

t k is the average temperature of air;
tke is the average ambient temperature;
ck and cke are respectively the average specific heat of air during 0~ t k and tke .
Table 4.16 Physical heat of air Q3

Physical heat of air Q3 kJ/ m3

1# BF hot stove

2# BF hot stove

325.11

308.77

4Heat taken in by cold blast Q4 :

Q4 c f 1t f 1 c fet fe

(4.9)

In the above: t f 1 is the average temperature of cold blast;

t fe is the average ambient temperature;
c f 1 and c fe are the average specific heat of air during 0~ t f 1 and t fe respectively.
Table 4.17 Heat taken in by cold blast Q4
Stove A (KJ/ m3)

Stove B (KJ/ m3)

235.78

282.74

Heat taken in by cold blast Q4 kJ/ m3

5Total heat input

Q
10

Q Q Q
1

Q3 Q4

(4.10)

Table 4.18 Total heat input

Total heat input

1# BF hot stove

2# BF hot stove

2567.62

2445.20

Q kJ/ m
3

Heat output items

1Heat taken out by blast Q1' :

Q1' c f 2t f 2 c fete

(4.11)

In the equation: t f 2 is the average blast temperature;

te is the average ambient temperature;

c f 2 and c fe are the average specific heat of air during 0~ t f 1 and t fe respectively.
'

Table 4.19 Heat taken out by blast Q1

1# BF hot stove

2# BF hot stove

1939.10

1923.30

'

Heat taken out by blast Q1

3

kJ/ m

2Physical heat taken out by flue gas Q2' is the principal heat loss of hot stoves:
Q2' BbVns (cy 2t y 2 cyete )

(4.12)

In the equation: t y 2 is the average flue gas temperature;

te is the average ambient temperature

c y 2 and c fe are the average specific heat of fume during 0~ t y 2 and te respectively.
'

Table 4.20 Physical heat taken out by flue gas Q2

1# BF hot stove

2# BF hot stove

465.49

383.04

'

Physical heat taken out by flue gas Q2

3

kJ/ m
11

3 Chemical incomplete combustion heat loss Q3 ' is the heat loss caused by the
unburned gas combustible in the fume flowing away with fumes
Q3 ' BbVns (126.36 COs ' 107.85 H2s ' 358.81 CH4s ' 931.81 C3H8s ' ) (4.13)

Table 4.21 Chemical incomplete combustion heat loss Q3 '

Chemical incomplete combustion heat loss Q3 '

1# BF hot stove

2# BF hot stove

0.14

3.40

kJ/ m

4Heat absorption amount of mechanical water in gas Q4' :

Q4' Bg mj [1.244(cq 2t y 2 cq1tm )] 103

(4.14)
'

Table 4.22 Heat absorption amount of mechanical water in gas Q4

1# BF hot stove

1# BF hot stove

0.73

0.34

'

Heat absorption amount of mechanical water in gas Q4

3

kJ/ m
'
5Heat taken out by cooling water Q5

Q5' C G s

V f f

t s 2 t s1 4.15

In the equation Gs -- the average cooling water flow rate in the test cycle
'

Table 4.23 Heat taken out by cooling water Q5

1# BF hot stove

2# BF hot stove

42.19

66.28

Heat taken out by cooling water

Q5' kJ/ m3

6Heat dissipation of hot blast tube surface

Q6'

Q6' K ( ti Ai ) /( f V f 1 f ) 4.16
'
Table 4.24 Heat dissipation of hot blast tube surface Q6

12

1# BF hot stove

2# BF hot stove

35.27

33.26

Heat dissipation of hot blast

tube surface

Q6' kJ/ m3

7Heat dissipation of stove surface Q7'

Q7'

V
f

q A
i

4.17

In the equation q i is the surface heat flow of certain stove parts

q i can be replaced with K ti .
'

Table 4.25 Heat dissipation of stove surface Q7

1# BF hot stove

2# BF hot stove

39.83

28.25

Heat dissipation of stove surface

Q7' kJ/ m3

8Thermal diagnostic difference Q

Q Q (Q1' Q2' Q3' Q4' Q5' Q6' Q7' ) 4.18

Table 4.26 Thermal diagnostic difference Q
1# BF hot stove

2# BF hot stove

44.87

7.33

Thermal diagnostic difference

Q kJ/ m3

5. Thermal diagnosis result:

Carry out the thermal diagnostic calculation for the hot stove system with the above
calculative process. Before the thermal diagnosis, first it ought to calculate the relative
error with formulas (5.1). The allowed relative difference rate in thermal balance is
prescribed as 5%.

Q
100%
Q

5.1

13

1#stove

44.87
Q
100% =
100% = 1.75%
2567.62
Q

2#stove

7.33
Q
100% =
100% = 0.30%
2445.20
Q

It can be seen that the relative error of thermal balance calculation for the two hot
stoves are less than 5%, so the calculative result is effective. Table 5.1 and 5.2 is thermal
diagnosis results.
Table 5.1 Thermal diagnosis result of 1# BF hot stove in Jingtang Co.
Heat input

Heat output

Symbol

Item

kJ/m3

Symbol

Item

kJ/m3

Q1

Chemical heat
of fuel

1859.03

72.41

Q1'

Heat taken out

by hot blast

1939.10

75.52

Q2

Physical heat
of fuel

147.70

5.75

Q 2'

Physical heat taken

out by flue gas

465.49

18.13

Q3

Physical heat
of air

325.11

12.66

Q 3'

Chemical incomplete
combustion heat loss

0.14

0.01

Q4

Heat taken in by
cold blast

Heat absorption
amount of mechanical
water in gas

0.73

0.03

Q 5'

Heat taken out by

cooling water

42.19

1.64

Q6'

Heat dissipation of hot

blast tube surface

35.27

1.37

Q7'

Heat dissipation on
stove surface

39.83

1.55

Thermal balance
difference

44.87

1.75

Total heat output

2567.62

100

Total heat input

235.78

2567.62

9.18

100

'
4

Table 5.1 Thermal diagnosis result of 2# BF hot stove in Jingtang Co.

Heat input

Heat output

Symbol

Item

kJ/m3

Symbol

Item

kJ/m3

Q1

Chemical heat
of fuel

1728.13

70.67

Q1'

Heat taken out

by hot blast

1923.30

78.66

Q2

Physical heat
of fuel

125.56

5.13

Q 2'

Physical heat taken

out by flue gas

383.04

15.66

14

Q3

Physical heat
of air

Q4

Heat taken in by
cold blast

6.

Total heat input

308.77

282.74

2445.20

Chemical incomplete
combustion heat loss

3.40

0.14

Heat absorption
amount of mechanical
water in gas

0.34

0.01

Q 5'

Heat taken out by

cooling water

66.28

2.71

Q6'

Heat dissipation of hot

blast tube surface

33.26

1.36

Q7'

Heat dissipation on
stove surface

28.25

1.16

Thermal balance
difference

7.33

0.30

Total heat output

2445.20

100

12.63

Q 3'

11.57

'
4

100

Analysis of the Results

1As shown in table 5.1 and table 5.2 above, comparing 1# hot stove without

coating and 2# hot stove with coating, the heat taken out by hot blast is increased from
75.52% to 78.66%, and heat taken out by flue gas is from 18.13% down to 15.66%. So the
proportion of the effective utilization of heat is increased, and the heat taken out by fume is
decreased.
2Calculate the ontological thermal efficiency of hot stove system:

Q1' Q4 Q6'
100%
Q Q4

1# BF hot stove 1

Q1' Q4 Q6'
100% 74.56%
Q Q4

2# BF hot stove 1

Q1' Q4 Q6'
100% 77.40%
Q Q4

Comparative data, the ontological thermal efficiency of 2# BF hot stove system with
coating is 77.40% and the thermal efficiency of 2# BF hot stove system without coating is
74.56%. The thermal efficiency of 2# BF hot stove system is 2.84% higher than 1# BF hot
stove.
3Two blast temperature is almost the same (blast temperature of 1# BF hot stove is
15

1304, and blast temperature of 2# BF hot stove is 1303). Compare gas consumption B
in blast per unit volume (see Table 4.13). Compared with 1# hot stove, the gas consumption
difference of per unit blast volume of 2# hot stove is a =|

0.53 - 0.58
| 100% = 8.62% .
0.58

Given the difference in gas calorific value of 1# and 2# BF hot stoves, suppose the gas
calorific value is the same of two stoves. So the gas consumption B in blast per unit volume
of 2# hot stove is 0.539, and the gas consumption difference 0.539 0.58 100% 7.07%
0.58

7.

Conclusion
1The average blast temperature difference is 1 between 2# BF hot stove with
coating and 1# BF hot stove without coating, and the heat utilization ratio of 2# hot
stove is 3.14% higher than 1# hot stove.
2Heat taken out by flue gas of 2# BF hot stove with coating is decreased 2.47%
compared with 1# hot stove without coating.
3The thermal efficiency of 2# BF hot stove with coating is 2.84% higher than 1# hot
stove without coating.
4Under the condition that two blast temperature is almost the same (1 difference),
the gas consumption of blast volume per unit area of 2# hot stove is decreased 8.62%
compared with 1# hot stove. The gas consumption is decreased 7.07% in consideration
of gas calorific value difference.

School of Metallurgical and Ecological Engineering,

University of Science and Technology Beijing

2011620
16