CUTTING CONSTRUINCTION
OF RESIDUAL PIG IRON INGOT
Nippon Concrete Cutting Co., Ltd.
5-5-50, Mizuhai, Higashi Osaka, Osaka, Japan
TEL：+81-72-960-5910 / FAX: +81-72-960-5911
Contact：KEISUKE MURATA
E-mail: [email protected]
http://www.concrete-cutting.jp
CONSTRUCTION SUMMARY
The volume of blast furnace which began operation in 1972 is scheduled to be increased from 4,250 ㎥
to 5,000 ㎥ . And the latest operation technique facility is also installed. In this renewal construction of blast
furnace, the major difficulties was solidified pig iron (about 1,500 ton) under the tap hole which was too big
to be carry out from the construction site in a state as it is. Then we take a method of diamond wire saw and
cut the solidified residual pig iron together with the furnace bottom section to small divided to a size to be
moved by crane (about 50 ton).
Hopper
Blast furnace gas downcomer
Large bell
Feed belt conveyer
Stock line
Coke
Iron ore sinter
Dust cyclone for separation
of solid particles
Throat
Hot blast
tube
Belly
Hot blast annual tube
Bosh
Cutting object
Cinder notch
Slag
Moltern iiron
Tuyere
Carry out together with furnace bottom.
Then cut and divide into small pieces
Blast furnace gas
Pig iron ingot
Hot blast
Shaft
Hot blast stove
Slag Car
Cold air
Tap hole
Torpedo Car
CUTTING OBJECT
⑧
⑪
⑨
⑩
⑦
⑥
⑤
⑨
④
⑧
③
⑦
②
⑥
①
⑤
④
③
⑪
②
①
⑩
Wire Saw
Pig iron：Fe 97.900％, Mn 1.390％, Si 0.314％, Al 0.253％, C 0.067％, S 0.003％,Other 0.073％
Cut No.
Length
Height
（m）
（m）
Cutting
Area
Cutting
Time
（m2）
（h）
Cut No.
Length
Height
（m）
（m）
186.6 ㎡
Cutting
Area
Cutting
Time
（m2）
（h）
①
6.5
1.7
11.0
29
⑦
10.5
1.7
17.8
38
②
9.3
1.7
15.8
104
⑧
9.2
1.7
15.6
48
③
11.2
1.7
19.0
101
⑨
6.9
1.7
11.7
12
④
11.5
1.7
19.5
36
⑩
10.9
1.7
18.5
27
⑤
11.4
1.7
19.3
48
⑪
11.6
1.7
19.7
31
⑥
11.0
1.7
18.7
61
Σ
110.0
186.6
535
Core drilling（The guidance hole of diamond wire）
Carbon Bricks： Φ65mm 11＠16.6m＝182.6m
CONSTRUCTION SITE
Kita Kyushu City, Fukuoka, Japan（See below map.）
CONSTRUCTION PERIOD / MANPOWER
June 14, 2014 – July 15, 2014 ‥ 32 days（Including 6 holidays）
※ All day and night continuous work
Construction site
8 persons × 26 days（Actual working days）＝ 208 persons
※ 4 persons (two shift operations）
MACHINE AND MATERIAL TO BE USED
Wire Saw Machine ：2000cc gasoline engine Wire Saw 50PS ‥ 2 (Two) machines
Quantity of diamond wire to be used
Wire
No.
Length
of use
（m）
Diamond wire specification
Hours of
use
（ｈ）
Cutting
Area
（m2）
Cutting
Speed
（m2/h）
Wire Life
（ｍ2/m）
Sintered/ Φ11.5mm /Number of beads:40 /m
50
50
25.0
29.0
13.8
11.1
0.55
0.38
0.28
0.22
3
Sintered/ Φ11.5mm /Number of beads:40 /m
50
37.0
11.4
0.31
0.23
4
Sintered/ Φ11.5mm /Number of beads:40 /m
5
Sintered/ Φ11.5mm /Number of beads:40 /m
6
Sintered/ Φ11.5mm /Number of beads:40 /m
50
50
50
26.0
38.0
7.0
8.1
5.9
3.6
0.31
0.15
0.52
0.16
0.12
0.07
7
Sintered/ Φ11.5mm /Number of beads:40 /m
8
Sintered/ Φ11.5mm /Number of beads:40 /m
9
Sintered/ Φ11.5mm /Number of beads:40 /m
50
50
50
10.0
31.0
20.0
5.5
16.3
8.4
0.55
0.53
0.42
0.11
0.33
0.17
10
Sintered/ Φ11.5mm /Number of beads:34 /m
50
25.0
7.8
0.31
0.16
11
Sintered/ Φ11.5mm /Number of beads:34 /m
12
Sintered/ Φ11.5mm /Number of beads:34 /m
13
Sintered/ Φ11.5mm /Number of beads:34 /m
50
50
50
34.0
17.0
24.0
16.1
9.8
15.6
0.47
0.58
0.65
0.32
0.20
0.31
14
Electroplate/ Φ10.8mm/ Number of beads:48/m
15
Electroplate/ Φ10.2mm/ Number of beads:48/m
16
Electroplate/ Φ10.2mm/ Number of beads:48/m
50
50
50
17.0
36.0
32.0
3.5
6.8
10.5
0.21
0.19
0.33
0.07
0.14
0.21
17
Electroplate/ Φ9.0mm/ Number of beads:48/m
18
Electroplate/ Φ9.0mm/ Number of beads:48/m
19
Electroplate/ Φ9.0mm/ Number of beads:48/m
75
50
50
29.0
51.0
41.0
11.4
7.7
7.7
0.39
0.15
0.19
0.15
0.15
0.15
20
Electroplate/ Φ11.0mm/ Number of beads:40/m
40
6.0
5.5
0.92
0.14
1,075
535.0
186.6
Avg. 0.35
Avg.0.18
1
Sintered/ Φ11.5mm /Number of beads:40 /m
2
∑
Core Drill Device：100V /2400W / General-purpose device ‥ 4 devices
QTY of Diamond bit to be used: Sintered Type 2・1/2“（Φ65mm）・・・ 18 pcs（Bit life：10.14m/piece）
SPECIAL CONSTRUCTION CONDITIONS
Confined working area / Narrow working space
Since working area is surrounded by the blast furnace equipment, work space is limited to the upper part of
cutting object.



Machineries are moved collectively by installing the cutting stand (W3.0m×L6.0m×H0.7m)
To achieve space-saving work on the cutting stand by installing the diamond wire winder
Maximum efficiency windings with space-saving by utilizing the principle of movable pulley
Wire saw
Winder
Cutting stand
Cutting stand
Installation of cutting stand (Wire Saw ・ Winder）
Hardness of Pig Iron and Cutting Speed
Based on past experience, we predict cutting speed is about 0.3m2/h and wire life is about 0.1m2/m.
However during the cut work, if the wire runs into deposit of metals which is used in the catalyst and the like,
both of cutting speed and diamond wire life are supposed to be reduced significantly.
Then we provided the diamond wire, not only sintered type (life-importance) but also some kinds of galvanized
type (cutting speed-importance) which are replaceable and different diameters.

Provide several kinds of diamond wire which are different diameters and different features

In consideration of wear of diamond, wounded to the object in 50m units.

Provide the special core bit for metal drilling
Analysis of pig-iron
Component
Pig Iron
Iron (Fe)
97.900％
Manganese
(Mn)
1.390％
Silicon (Si)
Aluminum (Al)
0.314％
0.253％
Carbon (C )
0.067％
Measurement of hardness
HRb : 57 (Vickers hardness equivalent: HV 100 ）
→ This pig iron has little impurity and soft. And its component is close to pure iron.
Sulfur (S)
0.003％
Others
0.073％
INNOVATIVE TECHNOLOGY
Greatly contributed to the expansion of the wire saw application from concrete to metal cutting.
To cut and divide thick and huge metal ingot into small pieces by Diamond wire saw method without using
the fire. (Cutting object is not a thin steel plate etc. but thick and huge metal ingot.)



No emission of poisonous gas
No risk of fire hazards because it does not use the fire.
No cutting restrictions by the thickness of a component and combined materials.
Oxygen gas cutting（Conventional method）
Metal cutting by Diamond wire saw
CONSTRUCTION QUALITY
Limited construction period: 40 days
Only 40 days were given as a removal construction period because of the next construction schedule.

Time saving by drilling the guidance hole of diamond wire into the fire brick.

To shorten the construction period by using two wire saw machines and day-and-night continuous operation

Selection of the blade edge after metal analysis
Drilling the guidance hole of Diamond wire
Block removal method
Since it is a metal ingot, it has about three times specific gravity as compared with the standard concrete.
Then we asked resin anchor manufacturer if they have any experience of placing anchor for metal (not
concrete). And we found that they don’t have any experience of that.
 Execution of the pull-out test of anchor bolts
 Anchor bolts are basically only used for removing of furnace bottom. At the time of carrying it out,
a suspended frame is used.
Anchor bolt pull-out test
Using hanging frame
CONSTRUCTION FLOW
① Before Construction
Blast Furnace (Before construction)
Moved out pig iron ingot bonded to furnace bottom
Marking of the cutting position
② Drilling the guidance hole of diamond wire
Drilling the guidance hole of diamond wire（Drill into carbon brick:@16.6m）
For the reduction of construction time, drill the carbon brick under pig iron
③ Installation of wire saw machine
Lifting of the cutting stand
Fine adjustment of cutting stand
Wire saw and Winder machine on the cutting stand
④ Cutting by Wire Saw
Installation of Diamond wire saw machine
Winder machine
The completion of wire saw machine installation
④ Cutting by Wire Saw
C
Cutting by wire saw （1）
Cutting by wire saw （2）
Cutting by wire saw （3）
⑤ Placing of the anchor for removal（for dynamic lift-off）
Drilling for placing of anchor
Placing M48 bolt
Pull-out load（586.5KN）
Epoxy resin injection
Pull-out test of anchor bolt
Placing of the anchor
⑥ Removing blocks
Removing the end part of block ①
Transport by trailer to a place where cut blocks
are kept temporary
Dynamic lift off block
The cutting line ① (immediately after removal )
Unloading blocks at temporary storage
Removing blocks by using hanging metal fitting
⑥ Removing blocks
Removing the cut blocks while measuring
Crack occurrence
Hanging metal fitting
(for the blocks which came to pieces)
Measurement of the cut block
Blocks are come to pieces by crack
Cutting lines remain since cut with to block
the carbon brick bonded to block
⑦ Completion of construction
Carbon brick removal（next work）
Carried out blocks
① Cutting Line
② Cutting Line
③ Cutting Line
④ Cutting Line
⑤ Cutting Line
⑥ Cutting Line
⑦ Cutting Line
⑧ Cutting Line
⑨ Cutting Line