Sample Projects
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Blast Furnace Repair
Middletown, Ohio
Summary of Scope of Service
ATSI was selected to provide engineering design for the repair of the No. 3 blast furnace. The scope of work included replacing the furnace top, a new hearth design, stave cooling in the bosh and lower stack, a new backdraft stack and general repairs.
Services Provided
- Provide thermal modeling to aid in selecting a best hearth bottom and wall design.
- Engineer a stave cooling water system.
Teresa Blast Furnace Repair and Upgrade
Location: Chimbote, Peru
Summary of Scope of Services
The “Teresa” Blast Furnace was upgraded to increase the capacity of the overall facility and to defer the next reline 3-5 years. The bulk of the work included upgrading the hot blast system and repairing a severely distressed bosh. The work was done in phases, with the bulk of the work performed during an 18 day outage on the furnace. Later phases involved the relining of each stove, one by one, while the furnace operated on two stoves. Total project value was approximately $20 million.
Services Provided
- ATSI provided overall project management, conceptual engineering, detail design engineering, purchasing for all materials, construction management, and construction supervision (down to foremen) of labor supplied by the client.
Furnace Proper
- Bosh bandaid repair on the spray cooled bosh
- 100 percent replacement of stack cooling plates
- New double chamber tuyeres and tuyere booster pump system
- Gunite repair from the tuyeres up
- New penstocks and blowpipes (for the higher HBT)
Stoves
- Three stove relines
- New burners and combustion air fans
- New stove control system Gas System
- New electrostatic precipitator control system and internals Stockhouse
- New stockhouse monitoring and charging control system
- Raw material sampling system
Blast Furnace No. 1 Stockhouse Automation
Weirton, West Virginia
Summary of Scope of Service
ATSI was contracted to perform the installation engineering for the automation of the stockhouse on Blast Furnace No. 1. The existing manually operated scale car based system could not support the material handling demands required by an increase in production rate to 4200 tons of hot metal per day.
The new automated material handling system integrated large vibrating feeders on the bottom of the existing material bins and utilized a network of conveyors, a custom designed shuttle car system and enlarged material weigh hoppers to load higher capacity skip cars. Numerous stockhouse structural modifications and changes to external retention bins were performed as part of this project. A new, separate Motor Control Center Building was designed to house the new switchgear and transformers. The associated schematics and loop drawings as well as conduit and cable schedules were provided.
Services Provided
- Conveyors employed (14 troughing and 5 elevating) to transfer material to and from screening stations and to fill weigh hoppers
- Design of a pneumatically controlled shuttle car system to load weigh hoppers
- Redesign of weigh hoppers to maximize active capacity and increase discharge efficiency
- Redesign of discharge chutes to increase flow rate to meet new timing requirements
- New self-checking weigh systems incorporated to accurately provide weight data to the main control system
- Design of a new MCC Building to house the new MCC's and transformers/switchgear
- Structural modifications (steel and concrete) to provide proper clearance for the new equipment.
- Girders/columns reworked and new foundations incorporated
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