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Kalugin shaftless hot blast stove with a small diameter pre-chamber at the top of
Blast Furnace Area the dome has become the further development of the dome combustion concept.
Gas is combusted in the ceramic burner device of “pre-chamber” type where the
Mini Blast Furnaces jet-vortex flow of gas and air is arranged in the vertical axis of the stove.
Kalugin's Shaftless Stoves
Annular headers of gas and air are arranged inside the brickwork of the KSS pre-
Rotary Charging Unit
chamber and the latter is independently supported on the dome shell. Such a
Blast Furnace Equipments design has been incorporated for the first time in BF No.1 of Satka Iron-Melting
Works in 1992, and the above hot stove has been operating failure-free up to the
Laddle
present moment.
Conventional Stoves
Numerous trials were carried out at special combustion and aerodynamic test
Energy Optimizing Furnace facilities for several versions of pre-chamber burner devices. According to the
Rolling Mill Area acquired data, the most reliable and suitable design of the pre-chamber burner
was selected from the viewpoint of technical parameters, and simplicity and
Rail Mill Area reliability of performance of the refractory lining as well.

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Furthermore, a method of 3D numerical computer calculation has been developed
Request for a Proposal based on those tests, a detailed comparison of calculated and experimental
results has been made and an excellent correlation was established. At present,
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calculations of all pre-chamber burner devices of Kalugin hot blast stoves is made
Our Clientele based on this 3D numerical computer calculation method.

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Jet vortex of gas and air in the pre-chamber ensures intensive and uniform mixing
Career & combustion of gas and the process of combustion is over in the middle part of
the dome before entering the checker-work. The optimum degree of jet vortex is
Contact us obtained experimentally and can also be verified through theoretical calculations.
Thus, unevenness of distribution of combustion products across the checker-work
surface does not exceed 3-5%.

Pre-chamber
burner
design for
each KSS is of tailor-made engineering, as well as that of the
optimum number of nozzles, their location and angle, gas and air
velocities and the degree of jet vortex are also calculated
individually. Based on the data obtained, the patterns of gas
combustion, temperatures and flow distribution are prepared and
subsequently engineering of the refractory lining and steel shell is
carried out.

It is obvious that gas combustion starts in the pre-chamber and

completes in the top part of the dome so that before entering the
checker-work, the gas is almost burnt out having the content of
carbon monoxide max 50 ppm. When gas is moving down the
checker-work, after-burning of remaining carbon monoxide occurs
and at the outlet of KSS the content of CO is less that 20 mg/m³.
Hence, the ceramic burner system of the pre-chamber ensures a
very intensive mixing and instant combustion of gas owing to the jet
vortex flow of gas and air.
Jet vortex flow distribution may be different for Kalugin hot stoves of different thermal capacities. Research work carried out in the
operating KSS with oxygen (O2) content in exhaust waste gas in the range of 0.3 to 5.1% during full thermal capacity operation have
shown that the jet-vortex burner ensures the content of carbon monoxide (CO) of 0.0016%, or about 20 mg/m3, which is 5 times less than
the European standards. The Kalugin ceramic burner performs better than the most commonly used slot-hole ceramic burner of DME
design (Germany).

Since there is no pulsating of combustion, it is possible to enhance

operating modes of KSS without great pressure fluctuations and
vibrations, and therefore, damage to brickwork and structures is
avoided.

Hydraulic resistance of the hot blast stove is insignificant and a

normally available pressure of gas (4.0-5.0 kPa) at the burner inlet is
sufficient for full capacity operation.

Jet vortex of gas and air in the pre-chamber of Kalugin hot blast
stove ensures an even combustion of gas and subsequent
distribution of flows of combustion products across the checker-work
surface and requires no adjustment of the ceramic burner before
commissioning. Refractory lining of most of the parts of KSS is quite
simple except that of the pre-chamber.

1 – Hot stove with the internal combustion chamber;

2 – Hot stove with the external combustion chamber (such as Didier-
Werke);
3 – Kalugin hot stove

Since there is no the direct impact of flame on

the brickwork in KSS, local overheating is
avoided and this also provides a symmetric
distribution of temperatures along the dome,
checker, refractory lining and steel shell.
Hence, the thermal stress on all design
elements is reduced significantly and the
service life of the stove is improved.

As measurements have shown, the average

level of temperatures in the pre-chamber
brickwork is low (about 900ºС on the average),
and fluctuations in temperatures of the
brickwork between the gas and blast periods
are close to fluctuations in temperatures in the
brickwork of the ceramic burners of the first
shaftless hot stove with the annular pre-
chamber (stove No.4 (23) of BF4, NTMK) which has been operated since 1982 without capital repairs and is still in a good condition. This
allows us to determine long term service life of the pre-chamber brickwork, and thus the Kalugin stove lifetime is specified by the service
life of the silica dome, which reaches 30 years without reline.

Design of the dome proper also promotes a longer service life at high temperature operation because the wider part of sphere above the
checker-work passes to the conical part and further to the narrow neck accomplished in the ceramic burner dome, which has a much
smaller radius and operates at relatively low temperatures. The diameter of the KSS dome having an independent support of its brickwork
on the shell, as compared with the typical hot stove, is only slightly wider, and therefore Kalugin hot stoves can be fit well into the
dimensions of existing stove units in case of their modification into a shaftless stove unit.

Cut-off valves of gas and combustion air were installed in the dome area in the first Kalugin dome combustion stove. Presently, new
arrangement and technological solutions are developed, in which all technological equipment of KSS system (hot blast valves, cut-off and
control valves of gas and air) is located either on the existing maintenance platforms at the bottom, or on new platforms in the upper part
 of the shell. As a rule, all equipment is located on one side of the hot stoves system and this reduces the space for its arrangement.
Technological equipment of KSS is serviced with lifting equipment installed in the Stove House. In general, the operation process of KSS
practically does not differ from the operation of conventional hot stove system.

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