Customized converter front capture hoods: A key line of defense in industrial dust control

Industries such as steel smelting play a crucial role in industrial production. However, the large amounts of high-temperature flue gas and exhaust gases generated during these processes pose not only a serious threat to the environment but also potential risks to workers' health. To effectively address this challenge, customized converter front capture hoods have emerged as a key line of defense in industrial dust control. This article will delve into the design, functionality, advantages, and importance of customized converter front capture hoods in industrial production.

Design and Structure of the Converter Front Capture Hood

1. Unique Design for the Converter Steelmaking Process

The converter front capture hood is a flue gas control device specifically designed for the converter steelmaking process. During the converter steelmaking process, iron charging, steel blowing, and steel tapping generate instantaneous high-volume, high-concentration, high-temperature flue and exhaust gases. The converter front capture hood is designed closely to these process characteristics. It utilizes a semi-enclosed or movable structure that dynamically coordinates with the converter mouth and can accommodate converter tilting operations, ensuring accurate flue gas capture under various operating conditions.

2. Precision Structural Components

Support Beam: As the backbone of the entire capture hood, the support beam plays a key role in structural stability. Made of high-strength material, it can withstand the hood's own weight as well as various external forces it may experience during operation, such as thermal expansion and mechanical impact, ensuring the hood remains stable in harsh industrial environments.

Double-Sided Inhalation Capture Hood: This is a core component of the capture hood. Its unique double-sided inhalation design significantly improves flue gas capture efficiency. When the converter is operating, flue gas surges from all directions. The double-sided suction capture hood captures flue gas from two opposing directions simultaneously, creating a powerful capture airflow that ensures more flue gas is quickly drawn into the hood and reduces fugitive emissions.

Baffle: The baffle further optimizes airflow within the hood. It directs the flue gas flow, allowing it to converge more orderly toward the suction port, preventing turbulence within the hood and improving capture efficiency. The baffle also acts as a barrier, preventing large particles from entering the suction port and protecting downstream equipment.

Suction Inlet: The suction inlet is the passage through which flue gas exits the hood, and its design directly impacts the capture efficiency. Appropriate suction inlet size and location ensure sufficient suction while creating a uniform negative pressure zone within the hood, effectively capturing flue gas. The suction inlet is typically connected to subsequent flue gas treatment systems, such as dust removal and desulfurization equipment, to purify the captured flue gas before release to the atmosphere.

Excellent Performance Features and Advantages

1. Efficient Production Without Interference

The converter front capture hood is designed with full compatibility in mind with production processes. Its installation and operation will not interfere with normal converter operations. During converter operations such as iron charging, steel blowing, and tapping, the capture hood seamlessly coordinates with the converter's tilting and rotational movements, achieving real-time, efficient fume capture and ensuring continuous and stable production.

2. Ultra-High Fume Capture Rate

Thanks to its unique structural design and optimized airflow distribution, the converter front capture hood can quickly store large amounts of fume, achieving an extremely high fume capture rate. High-temperature fume and exhaust gases generated during the converter steelmaking process are quickly drawn into the capture hood, effectively reducing fugitive emissions and minimizing harm to the surrounding environment and worker health. This highly effective fume capture capability makes the converter front capture hood a powerful tool for industrial dust control.

3. Strong High-Temperature and Impact Resistance

The high temperatures of converter flue gases, coupled with the presence of iron and slag splashing, place extremely high demands on the performance of the capture hood. The converter front capture hood is lined with refractory castables and features a water-cooled interlayer structure, providing excellent resistance to thermal radiation and mechanical shock. The refractory castable effectively blocks thermal radiation from high-temperature flue gases, protecting the hood's main structure. The water-cooled interlayer removes heat through circulating water, further reducing the hood's temperature and extending its service life. This robust resistance to high temperatures and shocks ensures the hood's long-term, stable operation in harsh operating environments.

Wide Range of Applications

1. Steelmaking Industry

During the steelmaking process, the converter is one of the main equipment producing high-temperature flue and waste gases. Customized converter front capture hoods can precisely capture flue gases generated during the iron-feeding, steel-blowing, and steel-tapping stages of the converter, effectively controlling dust emissions, improving the workshop environment, and protecting worker health. Furthermore, by reducing fugitive emissions, they help steel companies meet environmental regulations and achieve sustainable development.

2. Non-ferrous Metal Smelting Industry

Similar to steelmaking, non-ferrous metal smelting also produces large amounts of high-temperature flue and waste gases. The converter front capture hood is also suitable for use in converters, reverberatory furnaces, and other equipment in the non-ferrous metal smelting industry, efficiently capturing and treating flue gases, reducing environmental pollution and improving production efficiency and environmental performance.

3. Other High-Temperature Industries

In addition to the smelting industry, other high-temperature industries, such as glassmaking and ceramics production, also generate high-temperature flue and waste gases during their production processes. Converter front capture hoods can be customized to meet the specific needs of these industries, providing effective flue gas treatment solutions and helping companies achieve green production.

Installation and Maintenance Key Points

1. Installation Key Points

Precise Positioning: When installing a customized converter front capture hood, ensure that it precisely aligns with the converter furnace mouth. This requires strict measurement and positioning according to the design drawings to ensure the capture hood coordinates with the converter's tilting and rotation movements, achieving optimal flue gas capture.

Stable Installation: The support beam must be securely installed to prevent the entire capture hood from shaking or shifting during operation. During installation, use qualified connectors and fixtures to fully secure the support beam to withstand the weight of the capture hood and external forces during operation.

Sealing: To prevent flue gas leakage, all connections within the capture hood, such as between the support beam and the hood body, and between the air intake and the duct, require strict sealing. High-temperature and corrosion-resistant sealing materials can be used to ensure long-term, stable sealing.

 2. Maintenance Key Points

Regular Inspection: Regularly inspect the converter front capture hood, including the structural integrity of the support beams, damage to the hood body, and blockage of the baffles and air intakes. Promptly identifying and addressing potential issues ensures the proper operation of the hood and extends its service life.

Refractory Castable Maintenance: Inspect the wear of the lining refractory castable. If any peeling or damage is detected, repair or replace it promptly. Ensure that the refractory castable continues to effectively block heat radiation and protect the hood structure.

Water Cooling System Maintenance: For hoods with a water-cooled sandwich structure, regularly inspect the water cooling system. This includes checking the circulating water flow rate and temperature, and leaks in the cooling water lines. Maintaining the proper operation of the water cooling system is crucial to reducing hood temperatures and extending hood service life.

Cleaning and Maintenance: Regularly clean the hood to remove accumulated smoke, dust, and debris. This not only improves capture efficiency but also reduces corrosion, ensuring long-term stable performance.

Development Trends of Converter Front Capture Hoods

1. Intelligent Upgrades

With the continuous advancement of technology, customized converter front capture hoods will move towards intelligentization. Future capture hoods may be equipped with various sensors to monitor flue gas parameters such as temperature, flow rate, and concentration in real time, automatically adjusting the hood's operating status based on these parameters, achieving more accurate and efficient flue gas capture. Furthermore, intelligent systems can remotely monitor and diagnose faults, improving maintenance efficiency and reliability.

2. Energy-Saving and Environmentally Friendly Optimization

Amid the global advocacy for energy conservation and environmental protection, converter front capture hoods will continue to optimize their performance to reduce energy consumption and minimize their environmental impact. For example, improvements to structural design and airflow distribution can further enhance capture efficiency and reduce fan energy consumption. Furthermore, the use of more environmentally friendly materials and manufacturing processes can reduce carbon emissions during production and operation.

3. Further Customization

Different industrial enterprises have different production processes and equipment layouts, resulting in varying requirements for customized converter front capture hoods. In the future, converter front capture hoods will place greater emphasis on personalized customization, providing solutions tailored to specific enterprise needs. From size, shape to functional configuration, it can be deeply customized to meet the diverse needs of enterprises.

Process and key points of custom converter front capture hood

Why choose TIANKANG custom converter front capture hood custom

Efficient Gas Capture: The converter front capture hood boasts excellent gas capture performance, effectively capturing harmful gases generated during the production process, reducing pollutant emissions and environmental impact, while also improving work area air quality and safeguarding the health and safety of operators.

Optimizing Process Gas Quality: Customized capture hoods, through rationally designed airflow channels, precisely control the air flow entering the converter, resulting in more uniform airflow distribution within the furnace. This helps improve process gas quality, enhancing the efficiency and product quality of smelting and other related processes.

Extending Equipment Life: The capture hood may utilize an advanced water cooling system or other durable design to effectively lower equipment temperatures during operation, minimizing equipment wear and tear caused by factors like high temperature and corrosion. This extends equipment life, reduces equipment replacement frequency, and saves costs for the company.

Customized Design: TIANKANG can provide customized designs based on individual converter specifications, process requirements, site conditions, and other factors to better meet the user's specific production needs. Compared to standard products, it offers more precise functionality and a better user experience.

Easy Installation: These products may utilize a modular design, with each module prefabricated and tested in the factory. On-site installation requires only simple assembly, significantly reducing installation time and equipment downtime, thereby improving production efficiency.

Durability and Reliability: Customized products typically utilize high-quality materials and incorporate a variety of practical operating conditions into the design and manufacturing process to ensure excellent durability and reliability. This ensures stable operation over long-term production operations, reduces the frequency of failures, and reduces maintenance costs and workload.