Discover how Honeywell Technologies CCC helped a major steel producer modernise blast furnace air-supply control, increase blast pressure, reduce energy losses, and improve compressor reliability.
New Honeywell Technologies case study explores the modernisation of blast furnace control
Honeywell Technologies’ new case study explores how a major steel producer modernised its blast furnace air-supply control system to improve operational reliability, energy efficiency, and turbomachinery performance.
Addressing an industry-critical challenge
Blast furnaces depend on a steady and precisely controlled supply of compressed air to maintain combustion and support the production of high-quality molten iron. When this supply becomes unstable or difficult to control, the effects can extend across an entire steelmaking operation. Production can be disrupted, energy can be wasted and critical compressor equipment may be placed at greater risk.
The customer featured in the new case study was operating aging turbomachinery and blast furnace air-supply systems. Its existing automatic controls were outdated and relied heavily on the knowledge and experience of individual operators. The systems also struggled to manage important air-supply parameters efficiently and lacked dependable antisurge protection.
These limitations contributed to operational disturbances, energy losses, and an increased risk of equipment failure. The producer therefore needed a modern control solution that could improve automation and stability while remaining compatible with its existing turbomachinery infrastructure.
Introducing a modern digital control solution
Following a competitive evaluation involving domestic and international suppliers, CCC was selected to design and implement an automatic control system for the plant’s blast furnace air supply.
The proposed solution combined a fully digital, microprocessor-based control platform with proprietary hardware, software, and patented control algorithms. One of the central elements of the project was CCC’s digital electric-to-hydraulic transducer, which enabled precise, high-speed control of the plant’s existing hydraulic actuators.
This approach allowed the producer to introduce modern control capabilities without replacing valuable installed equipment. The new platform was designed to support more accurate blast furnace control, improve compressor protection, and provide greater stability across the operation.
Improving control, protection, and stability
The results outlined in the case study demonstrate the potential impact of modernising critical turbomachinery controls. Following implementation, the producer achieved tighter rotational speed and compressor discharge pressure control. Furnace blast pressure also increased beyond the improvement targeted at the beginning of the project.
The system delivered several additional operational benefits, including more effective antisurge protection, smoother pressure transitions during stove switching and improved recording of measured parameters during critical events. It also helped reduce wasteful bypass flows and allowed the compressor to operate more efficiently while remaining safely protected from surge conditions.
Supporting wider steelmaking performance
Higher blast pressure can create wider benefits for steel producers. Industry data referenced in the case study connects improved blast pressure with potential increases in production, lower coke consumption, and reduced emissions.
The report also examines how improved blast generation and utilisation may contribute to lower heat consumption, fuel savings, and reduced blast losses.
Rather than focusing only on the installation of new technology, the case study demonstrates how a carefully planned control retrofit can extend the value of existing infrastructure. It provides an example of how steel producers can use advanced automation to strengthen reliability, improve efficiency, and establish a more stable foundation for future operations.
A model for future modernisation projects
The project has also attracted interest from other steel producers considering similar improvements to compressor control, antisurge protection, and blast furnace air-supply systems.
The complete case study provides further information about the customer’s challenges, CCC’s technical approach, and the operational results achieved following implementation.
Explore the complete case study
To discover the full project results, technical approach, and industry performance data, explore the Honeywell Technologies case study here.