Operation of Blast Furnace is quite complex in nature that relies on multiple technological aspect. To keep its operation in the safe zone it has to be operated non-stop on its rated capacity. Extended low production process is very detrimental for Blast Furnace refractory which unfortunately has been done perforce during last couple of years due to shortage of raw material. It has to be realised that Pakistan Steel Mills Blast Furnace No 1 was relined in 1996 and from then it is being operated continuously. As per the experts opinion, the normal refractory life of the Blast Furnace is 18 to 20 years. So Blast Furnace No 1 is already mature for its complete relining. As the furnace was operated at a very low capacity during the last 3-4 years that has scratched the inner profile of the furnace.
Under these conditions there certainly exist some weak areas especially in the hearth of the furnace which encounter very high degree of temperature ie 1500-1600°C and highly corrosive slag which may blow-up during operation in specific circumstance as stated above. When the production rate is being boosted up, the weak areas inside the furnace are exposed and such an incident can occur as happened on 9th October 2014 at Blast Furnace No 1. However, it is a routine process failure that can happen in such a huge process industry. The state of affairs is, however, being tackled with extraordinary skill and proficiency coupled with hard work of PSM engineers and technicians.
PSM senior management and Executive Management Committee are very cautions in the matter and intimately monitoring the restoration work round the clock to restart the furnace in the minimum possible time. A facts finding investigation has been ordered immediately after the incident to unearth the route causes of the incident and to find out the person(s) responsible, if any and to suggest the steps to be taken to avoid re-occurrence of such incidents in future.
PSM Management is much confident to regain its pace of production at Blast Furnace No 1 within next couple of days. PSM Management is also in close liaison with the Government to arrange the essentially required funds to carry out the capital repair of some of its major units including blast furnace No 1 & Steel Converters. Documentation and spade work is being completed on a fast track so that after getting clearance from the government these capital repairs can be taken up on priority for achieving sustainable and reliable production from the units.