Analysis of the Causes and Consequences of Resonance Accidents in Blast Furnaces

Abstract

Introduction. The blast furnace, together with hot-blast stoves and gas-cleaning equipment, remains one
of the most hazardous systems in the metallurgical industry. Accidents with catastrophic consequences
for both equipment and personnel require special attention. Such events have no statute of limitations and shall be thoroughly analyzed to eliminate their root causes and to ensure safe future operation.
Problem Statement. The technical literature has offered insufficient or even contradictory coverage of particularly severe accidents — especially furnace explosions — which hinders the improvement and development of safe blast furnace operating technologies. Therefore, the identification of effective methods for preventing and mitigating such emergencies is of critical importance.
Purpose. To determine the actual mechanism of the explosive destruction of Blast Furnace No. 7 at the Dniprovsky Metallurgical Plant (DMP) on September 7, 1993, taking into account both objective and subjective contributing factors.
Materials and Methods. The analysis is based on archival materials presenting the furnace operating parameters on paper records, photographic documentation, reports and conclusions of expert commissions, as well as relevant publications on the subject.
Results. The mechanism of the explosive destruction of BF No. 7 at DMP (Ukraine) has been reconstructed, and the contributing factors have been systematized. A comparative analysis of this accident and the incident at BF No. 5 at the Port Talbot plant (UK) has been performed. Both incidents were triggered by the same catastrophic mechanism: the uncontrolled entry of a critical amount of water into the furnace working space.
Conclusions. It has been established that the large-scale destruction of BF No. 7 at DMP with multiple human casualties resulted from two explosions of different intensities rather tham from a single explosion, as previously assumed. The dynamics of the changes in the blast furnace gas-blowing regime during the blow-in period have been demonstrated. It has been shown how, in the absence of burden descent at the furnace top, they led to an explosive accident. The study has emphasized the critical importance of adhering to established recommendations for preventing steam explosions in blast furnaces. The findings have represented a valuable contribution
to the development of regulatory documents aimed at ensuring the safe operation of blast furnaces.