Project Portfolio

Blast Furnace Cast House Modification

Project Description:
Casthouse is one of the most important parts of iron production and an important connection between the Blast Furnace and Steel Shop. Upon leaving the Blast Furnace iron separates from slag in main iron troughs. They get separated due to different weights. Iron and slag are transported into ladles via system of runners coated with refractory material. Ladles transport iron and slag to Steel Shop.

According to the initial solution for Blast Furnace No. 4, casthouse had intersecting systems of iron and slag runners. New disposition of runners is adjusted to iron casting on two sides. Iron is being cast to the right side via existing tilting runner and to the left side, also via tilting runner, which was relocated. After separation of iron and slag in the main trough, slag flows through secondary runners along the furnace central line, straight into the slag granulation chamber. Slag granulation chamber is part of the Direct slag granulation facility which is located outside of the casthouse. In case of some defect or refurbishment of the slag trough it is possible to open lateral emergency runner which can transport slag into emergency pit (volume 500 m3). Crystal slag would be manufactured in the emergency pit.

Also, in case of refurbishment of the main intersection point of the left and the right slag runner it is possible to cast from left taphole by usage of by-pass runner which leads to the emergency pit. Main troughs are pentagonal and serve for separation of iron and slag. Also, they are enabling better balancing of steel temperature and trough cooling. Slag and Iron Troughs are cooled by air. Cooling of runners is done by circulation of air at their bottom and lateral sides. Inflow of fresh air is provided from the area located below the casthouse. It is required to open platform floor under runners in order for air to circulate freely. Surface of casthouse platform is coated with refractory brick, flat (it follows slope of trough). The reason for that was so that the mechanization moved over the platform without any obstructions.

Scope of Work:
  • Basic and detail design of Cast House Modification
  • Basic and detail design of Troughs and secondary runners
  • Manufacturing of troughs and runners
  • Manufacturing of tilting runner with steel structure
  • QA During Manufacturing
  • Civil works on modification of the platform
  • Erection and commissioning
  • Start-Up
  • Testing
  • Training of Production and Maintenance personnel


  Casthouse system is dimensioned according to the following data:
  • Furnace process volume 1764 m3
  • Casthouse platform length 43 m
  • Casthouse platform width 36 m
  • Level of tapholes 9.5 m
  • Angle between tapholes 54°
  • Number of pouring per day 7 to 10
  • Daily production of hot metal 3150 to 3600 MT/day
  • Amount of hot metal per pouring 400 MT/pouring
  • Amount of slag per one MT of metal 390 to 430 kg/MTHM
  • Amount of slag 1200 to 1550 MT/day
  • Temperature of hot metal 1440 to 1460o C
  • Temperature of slag 1450 to 1550o C
  • Tapping time 90 to 120 min
  • Discharge rate of hot metal from
  • taphole 3 to 7 MT/min
  • Discharge rate of slag from taphole 3 to 8 MT/min
  • Max discharge rate of slag from
  • taphole during tapping