CERI: Enhancing Core Technologies for Green, Efficient, Professional, and Integrated Ironmaking with Longevity
Capital Engineering & Research Incorporation Limited (hereinafter referred to as "CERI") is dedicated to strengthening its core functions, enhancing capabilities, and continuously improving its competitiveness and long-term value realization. In the field of ironmaking, CERI has successfully completed more than 350 blast furnace projects over the past decades, developing a range of green, efficient, professional, and integrated ironmaking technologies with longevity.
Green and Efficient Storage & Transportation Process and Real-time & Balanced Feeding Technology for Stockyards (internationally advanced)
Introduction
This technology creates an efficient trunk-and-branch conveying network with direct feeding capability, enabling "real-time" material supply to users. It reduces land use for "materials to be supplied in real time", incorporates the technologies of Internet of Things (IoT) and big data, and optimizes feedstock storage through an optimal balanced storage model to enhance safety and efficiency. By analyzing the multi-directional feeding paths of feedstock users and the series and parallel connections of trunk and branch lines, this technology enables real-time, efficient, and environmentally friendly feeding and operations at reduced costs through a shared conveying network, intelligent route selection, and clean transfer. The technology has been granted eight patents, and its innovative achievements have been recognized as internationally advanced according to industry evaluations.
The technology is applicable to feedstock storage and transportation in iron and steel enterprises, covering all processes from receiving and unloading to storing, batching, and feeding.
Typical Project 1: Stockyard of Shougang Jingtang
Highlight I: Reduced land occupation: The land occupied for the centralized feedstock storage is reduced by 10%–20%.
Highlight II: Reduced investment and operating cost: The conveying equipment is reduced by 25%–30%, the length of the conveying line is shortened by 20%–25%, and the comprehensive energy consumption is decreased by 10%.
Highlight III: Reduced emission: The crushing rate of materials transferred at a single point is reduced by 85%, while dust generation during the same process is decreased by 50%–95%.
Typical Project 2: Stockyards of Linyi Special Steel
Highlight I: The new efficient storage and transportation process, featuring multiple branch lines and a direct feeding system, integrates seamlessly with the logistics network to create comprehensive stockyards with diverse types and functions. Type B stockyard is a fully enclosed facility featuring a grid structure with bolted spherical joints and has the largest span of its kind in China.
Highlight II: The intelligent management and control platform of the stockyard has been extended to encompass the entire pre-ironmaking integration area, featuring a three-level system for operation, control, and management. Highly intelligent performance iteration is achieved through upgrades in digitization and informatization.
Highlight III: A clean unloading, storage, and transportation system with ultra-low emissions has been established by integrating new solutions and technologies at transfer points. The spillage during conveying is reduced by 90%, the power consumption for dust removal is decreased by 40%–50%, and the number of workers required for cleaning is cut by 90%.
Economic indicators: This technology reduces stockyard investment cost by 10% to 25% and decreases the fund occupation cost of feedstock by 10% to 15% for the enterprise.
Next-Generation Green and Low-Carbon Rotary-Cutting Top-Burning Hot Stove Technology with Longevity (internationally leading)
Introduction
The rotary-cutting top-burning hot stove is a green, low-carbon technology developed by CERI over two decades. It features high blast temperatures, exceptional efficiency, and a long service life. This innovative stove incorporates several advanced technologies, including a high-efficiency low-carbon and low-nitrogen burner, a segmental furnace structure, interlocking airflow-equalizing checker bricks, a cross-beam grate with multiple hole patterns, constrained and guided hot-blast piping, recovery of exhaust gas from pressure discharge for pressurization and stove changing/firing model, time-shared preheating, and parallel connection of "one combustion for two heat supplies". Under the condition of single-burning blast furnace gas, the following objectives are achieved: air supply temperature ≥ 1,250°C, thermal efficiency of the hot stove system ≥ 88%, heat consumption per unit heating air volume and unit air temperature ≤ 1.52 kJ/Nm3/°C, and NOx concentration in flue gas ≤ 25 mg/m3. A total of 81 patents have been filed for this achievement, resulting in the granting of 11 invention patents (including 2 overseas patents), 1 software copyright, and 40 utility model patents, all of which are protected by independent intellectual property rights.
This technology has received achievement appraisal from the Chinese Society for Metals and MCC, attaining an internationally leading level.
The technology is suitable for new and reconstructed hot stove projects in the iron and steel industry, as well as for gas heating applications in the petrochemical industry.
Typical Project 1: Project of Tianjin Rongcheng
Highlight I: High air supply temperature: The air supply temperature is 1250°C or higher, effectively reducing the fuel ratio of the blast furnace.
Highlight II: Low coal gas consumption: The heat consumption per unit heating air volume and unit air temperature of the hot stove is 1.52 kJ/Nm3/°C.
Highlight III: Low emission of nitrogen oxides: The average emission concentration of NOx in flue gas is 19.4 mg/m3.
Typical Project 2: Project of Hansteel Nengjia
Highlight I: High air supply temperature: The air supply temperature is 1220°C or higher, effectively reducing the fuel ratio of the blast furnace.
Highlight II: Low coal gas consumption: The heat consumption per unit heating air volume and unit air temperature of the hot stove is 1.48 kJ/Nm3/°C.
Highlight III: Low emission of nitrogen oxides: The average emission concentration of NOx in flue gas is 15 mg/m3.
Economic indicators: This technology reduces the cost per ton of iron by approximately RMB 10.
Dry Process for Full Recovery of Blast Furnace Top Pressure Equalizing Gas (internationally leading)
Introduction
The technology utilizes a "high-efficiency injection device + a three-stage dust removal and purification system" and an "intelligent coupling control system based on time and pressure" to purify gas released during pressure equalization at the blast furnace top and recover it into the purified gas pipeline. This enables efficient and high-quality full gas recovery, preventing environmental pollution from pressure discharge, dust, and noise. Additionally, it generates economic benefits through the recycling of purified gas, thereby reducing the cost per ton of iron. The technology has received 11 domestic patents, including 3 invention patents, and has attained an internationally leading level according to the appraisal.
The technology is suitable for newly built and reconstructed blast furnaces of all sizes and types.
Typical Project: Project of Valin Lianyuan Iron & Steel Co., Ltd.
Highlight I: The gas recovery rate reaches 100%.
Highlight II: The recovery time is shortened by 11 to 14 seconds, with no impact on the charging operation rate of the blast furnace.
Highlight III: The dust content of the purified gas is lower than 5 mg/Nm3.
Highlight IV: The system operation noise is lower than 85 dB(A).
Economic indicators: The three blast furnaces can recover approximately 82 million cubic meters of gas annually, generating an economic benefit of around RMB 10 million per year.
Environment-friendly and High-efficiency Blast Furnace Slag Treatment through Bottom Filtration (internationally advanced)
Introduction
In view of a series of common problems such as poor filtration effect, high energy consumption, large amount of water replenishment, and corrosive steam pollution in the existing process of slag flushing with water, this technology has led to the innovative development of several equipment solutions, including an environment-friendly bottom filtration process for blast furnace slag treatment, a new steam recovery system, and an intelligent slag grabbing system, achieving low energy consumption and efficient water resource recycling. The technology has secured 42 domestic patents and 4 international invention patents, with the core patent receiving the Chinese Patent Excellence Award, and has attained an internationally leading level according to the appraisal.
The technology can be utilized for treating blast furnace slag in the metallurgical industry.
Typical Project: Project of an Iron and Steel Enterprise
Highlight I: Good product quality: The finished water-granulated slag product has a glass transition rate of ≥ 97% and a moisture content of ≤ 11% (only 65% of the moisture content obtained through mechanical methods).
Highlight II: High reliability: The granulating tower is used for safe and reliable slag flushing, with a swinging slag runner. The circulating water quality is excellent, with average suspended solids at ≤ 10 mg/L, less than 1% of that achieved by mechanical methods. Additionally, the wear loss of related facilities is minimal, resulting in a long service life.
Highlight III: Water saving and low consumption: Fresh water consumption per ton of slag is ≤ 0.8 t, approximately 60% of that used by mechanical methods, while power consumption is 80% of that of mechanical methods.
Highlight IV: The production process exhibits strong fault tolerance, with relatively loose product requirements and a wide adjustable range for slag flushing parameters. It serves dual functions of filtration and slag storage, allowing for extended maintenance intervals with minimal impact on blast furnace operations.
Highlight V: Low operating cost: The system is straightforward, requiring minimal equipment and maintenance.
Highlight VI: Excellent environment: The filter tank features a mobile sealing cover, water-free slag grabbing, and white smoke elimination facilities, enabling zero steam emissions and an improved environment.
Highlight VII: High degree of automation: The automatic slag grabbing crane can be coordinated through one-click operation, enabling unmanned production.
Highlight VIII: New modular filtering basin: "Breaking up the whole into parts" - The modular filtering unit replaces traditional cobblestone filtering materials to ensure effective filtration, achieving an average slag content of circulating water of ≤10 mg/L. The bottom is designed to be reliably leak-proof, while the upper section prevents backflow and scattering of filtering materials. The filter layer is positioned overhead, with a hot water buffer pool located below. Effective and stable liquid level detection minimizes the risk of air pumping in hot water pumps, with a slag accumulation prevention piping system at the bottom of the basin. The time consumption is reduced, with no impact on blast furnace production. The basin can be replaced step by step during the slag flushing period of the adjoining filtering basin, requiring no disassembly or assembly and allowing for easy hoisting. The quantity is small, with about 30 pieces for a single basin. The total replacement time is approximately 15 minutes per piece. The basin is reusable and impact-resistant, and offers a long service life with low maintenance costs. The equipment is reusable, requiring only the replacement of the filtering material. Compared with traditional bottom filtration, the total amount of filtering material is reduced by 68%. The stable structure is resistant to grab impact, with a service life of more than 1 year.
Hydrogen-rich Injection Technology for Blast Furnace and Sintering
Introduction
The hydrogen-rich injection technology for blast furnaces has been continuously developed to establish a technical route with independent intellectual property rights, supporting the steel industry in implementing "carbon peaking and carbon neutrality" actions, addressing carbon tax policy challenges, and achieving sustainable development.
(1) Various calculation models for hydrogen-rich fuel injection and smelting process in blast furnaces have been developed, enabling a comprehensive understanding of the changes in smelting conditions following hydrogen-rich fuel injection and the associated regulatory mechanisms.
(2) Key technologies and equipment for hydrogen-rich fuel injection in blast furnaces have been developed, along with a comprehensive understanding of various injection processes and relevant engineering verifications.
(3) The system is simple, occupies less land, and requires a smaller investment, making it suitable for both the reconstruction and new construction of blast furnaces.
(4) Comprehensive metering and control measures facilitate flexible operation in blast furnace production.
(5) Reliable safety measures ensure the system operates safely through intelligent control.
(6) Efficient process facilities can accommodate significant variations in injection volume while ensuring stable pressure and accurate metering.
The technology is applicable to all grades of blast furnaces.
The hydrogen-rich injection technology for sintering effectively addresses issues such as local enrichment and ignition, low injection amounts, and potential safety hazards. This is achieved through self-developed systems, including a hydrogen-rich fuel gas mixing system, a safety device, and an adjustable injection device. The technology enables safe, stable, continuous, and high-volume injection of hydrogen-rich fuel gas to the sintering charge level, significantly reducing solid fuel consumption and CO2 emissions during sintering production. This technology has received 6 domestic patents, including 3 invention patents.
The technology is suitable for sintering machines of various sizes and types.
Typical Project 1: Hydrogen-Rich Project for Blast Furnace of an Iron and Steel Enterprise
Highlight I: Hydrogen-rich tail gas or coke oven gas (COG) is used in the Project.
Highlight II: The 32 tuyeres of the blast furnace are all equipped with hydrogen-rich gas injection devices.
Highlight III: Hydrogen-rich tail gas ≤ 16,000 Nm3/h, COG ≤ 30,000 Nm3/h (source gas volume limits).
Highlight IV: Hydrogen-rich gas and pulverized coal are simultaneously injected.
Highlight V: The replacement ratio is estimated to be 0.3–0.4 kg/Nm3, the fuel ratio is reduced by 24–32 kg/t (COG), and CO2 emissions are reduced by approximately 3.2% (COG).
Typical Project 2: Hydrogen-rich Sintering Project of an Iron and Steel Enterprise
Highlight I: The forced release system is employed to rapidly and forcibly release the gas from the safeguarding gas compartment in the event of an accident, effectively mitigating the potential safety risks associated with emergency shutdown.
Highlight II: The safeguarding gas compartment is used to shield the coal gas from ambient airflow disturbances, ensuring its unimpeded passage through the charge level of the sintering machine. Additionally, the safeguarding gas compartment is interlocked with the main exhaust fan, and pressure detection is implemented within the compartment to maintain a negative micro-pressure under working conditions, thereby preventing gas overflow.
Highlight III: Flame detection is implemented in the safeguarding gas compartment to enable timely identification of nozzle fires. Ambient CO detection is provided, and the gas main is equipped with pressure detection and a gas quick-cut valve to mitigate safety risks.
Highlight IV: The safeguarding gas compartment is equipped with an airflow distribution plate and fire protection device to ensure sufficient time and space for uniform mixing of hydrogen-rich gas. A large wide-angle diffuser nozzle and a nozzle height adjusting device are incorporated to successfully mitigate the ignition risk posed by local fuel gas enrichment, enabling continuous, stable, uniform, and high-volume injection of hydrogen-rich fuel gas.
Technical indicators: Using COG as an example, the injection amount is 1.5 m3/t, which reduces coke powder consumption by 1.0–2.5 kg/t and CO2 emissions by 3.67–9.17 kg/t.