Blast Furnace and Air Separation Integration Using Redundant Blowers
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Solution Overview
Problem
The existing methods for increasing oxygen requirements in cast iron production, such as adding new blast furnaces or increasing fuel usage, often necessitate costly investments in new oxygen production units, and there is a need to efficiently utilize existing equipment to manage airflow and compressor redundancy in blast furnace operations.
Innovation Solution
The method involves using redundant air compressors to supply both the blast furnaces and the air gas separation unit, with a second compressor taking over when a primary compressor's airflow falls below a minimum threshold, allowing for flexible operation and reduced airflow during standby periods, and utilizing existing equipment to maintain production continuity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If new oxygen production units are added to increase oxygen requirements, then oxygen production capacity is improved, but investment cost increases
Solution Approach 1:
The patent applies multi-functionality by enabling redundant compressors to serve dual purposes: supplying air to blast furnaces during normal operation and supplying air to air gas separation units for oxygen production when needed. This allows existing equipment to be used for multiple functions, avoiding the need for additional dedicated oxygen production units and reducing investment costs while maintaining oxygen production capacity.
Solution Approach 2:
The patent changes the operational parameters of existing compressors by adjusting their airflow distribution between blast furnaces and air gas separation units. By dynamically modifying compressor output parameters and switching connections based on operational needs, the system can increase oxygen production capacity without adding new equipment, thereby avoiding increased investment costs.
2Reliability
If redundant compressors are used to ensure continuous production, then production reliability is improved, but device complexity increases
Solution Approach 1:
The patent reduces device complexity by making redundant compressors multi-functional. Instead of having dedicated standby compressors that sit idle or require complex switching mechanisms, the compressors are configured to automatically serve both blast furnaces and air gas separation units based on operational conditions. This universal usage simplifies the overall system configuration while maintaining production reliability.
Solution Approach 2:
The patent recovers the utility of redundant compressors by utilizing them for oxygen production through air gas separation units during periods when primary compressors are sufficient for blast furnace operation. This recovery of idle capacity maintains production reliability without requiring additional complex redundancy systems, as the redundant compressors are productively engaged during standby periods.
3Ease of manufacture
If existing equipment is utilized to meet increased oxygen demand, then investment cost is reduced, but equipment utilization flexibility is worsened
Solution Approach 1:
The patent applies dynamics by implementing flexible, dynamic switching mechanisms that allow compressors to adapt their function based on real-time operational needs. The system can dynamically redistribute compressor airflow between blast furnaces and air gas separation units, and can switch which compressors serve which equipment. This dynamic adaptability maintains equipment utilization flexibility while utilizing existing equipment to reduce investment costs.
Solution Approach 2:
The patent maintains equipment utilization flexibility through parameter changes by adjusting compressor airflow rates, pressure settings, and connection configurations based on demand. Existing equipment can be flexibly reallocated by modifying operational parameters rather than physical configurations, allowing the system to adapt to varying oxygen demands while avoiding new investments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables efficient use of existing compressors to maintain airflow and oxygen production, reducing the need for new equipment investments and ensuring continuous operation by adapting compressor usage and airflow distribution between blast furnaces and the air gas separation unit.
Implementation Method 1
a cryogenic air separation unit producing oxygen of industrial purity
Implementation Method 2
To bring the ambient air to this pressure, very powerful air compressors or 'blowers' are used
Implementation Method 3
coke (between 250 and 500 kg per tonne of cast iron), pulverized coal injected at the level of the nozzles, with an injected quantity which can vary between 0 and 250 kg per tonne of cast iron, or any other fuel such as natural gas, fuel oil
Data Source
AI summary
The invention relates to a method of integrating a plurality of blast furnaces with a plurality of air gas separation units, in which the replacement blower available on the blast furnace site is used to feed compressed air into an air gas separation unit making it possible to enrich the blast-furnace blast with oxygen, this unit being stopped when one of the blowers of the blast furnaces has to be replaced with the blower used by the air gas separation unit.