Back Ground
JSW Steel
India
JSW Steel, the flagship business of the diversified JSW Group, is India’s leading steel manufacturer with a current production capacity of 28.5 million tonnes per annum, aiming to increase to 38.5 million tonnes by the financial year 2025. Operating the largest single-location steel plant in Vijayanagar, Karnataka, the company drives innovation by partnering with JFE Steel of Japan, offering high-value steel products for construction, infrastructure, and automobiles. Renowned for its operational excellence and sustainability practices, JSW Steel has received global recognition from the World Steel Association and the S&P Dow Jones Sustainability Index.
Challenge
JSW Steel contacted Giant Inflatables Industrial to design and fabricate an inflatable isolation plug solution to isolate the inlet of a cyclone vessel in a steel factory’s blast furnace during the shutdown. They aim to create a barrier using an inflatable isolation plug to prevent residual blast furnace gases from moving into the work area, even after purging the system with nitrogen. The inquiry highlights a concern about the movement of burning gases from residual coke due to suction, which has occurred despite prior purging efforts. The inflatable plug must endure temperatures of 100-120°C, as it will be in contact with refractory-lined surfaces.
Key requirements:
The inflatable plug would be deployed during system shutdown.
It must withstand contact with 100-120°C refractory lining.
The plug will be placed at the inlet of the cyclone vessel to create an effective barrier.
The solution aims to address gas movement caused by residual burning coke.
Inflatable Isolation Plug
The inflatable isolation plug, designed and fabricated by Giant Inflatables Industrial for JSW Steel, is a robust solution. It is engineered to seal the inlet of a cyclone vessel in the blast furnace during system shutdowns. The plug features a triple-layer insulation system composed of woven fibre cloth, ceramic fibre, and another layer of woven fibre cloth, ensuring it can withstand temperatures of 100-120°C while in contact with the refractory lining. This high-temperature resilience, coupled with a reflective heat shield, enhances the plug’s ability to resist the heat from the furnace, making it a durable and reliable safety measure.
The plug is equipped with an inflation pipe and deflation zips, enabling efficient deployment and a secure fit within the vessel to prevent gas leakage. A key feature is its ability to maintain pressure even during a power outage, thanks to an internal design that allows the tubes to collapse and create a seal when the blowers are off.
Results
Specifically engineered to address the risk of residual blast furnace gas movement caused by burning coke, the plug creates a reliable barrier when placed at the cyclone vessel inlet, ensuring safety for maintenance personnel.
The inflatable plug plays a critical role in ensuring safety during maintenance at JSW Steel. Preventing hazardous gas exposure for personnel entering the blast furnace for maintenance significantly reduces the risk of accidents and ensures a safe working environment.
A closer look
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