Peel Jones Copper Products undertook a redesign to improve a critical component used as the nozzle to blast air into the furnace during steel production.
Component
Blast Furnace Tuyere, weighing 229 kg
Alloy
- Copper BS6017
Customer Requirements
- Ability to withstand a very aggressive environment within a blast furnace, utilising complex internal cooling channels.
Method
- Sand casting and CNC tooling
- CAD and casting simulation to optimise design and casting method
Outcome
- Optimised design through fluid flow and heat transfer modelling.
- Tighter tolerances in wall thickness achieved.
- Productivity increased by 100% (through reduced mould and core variability).
- 16% reduction in scrap and yield increased by 17%.
- Final component weight saving of 15kg (81kg reduction in poured weight).
- Future developments planned to include additive manufacture of core segments and further use of protective coatings to increase service life.
