Technological breakthroughs

The “Blast Furnace Innovation for Fused Phosphate Fertilizer Production” initiative by Ninh Binh Phosphate Fertilizer Joint Stock Company focuses on improving gas flow and the furnace’s heat retention. The solution reduces heat loss, enhances fuel efficiency, and improves working conditions for employees.

Optimising Gas Flow, Reducing Heat Loss

Fused phosphate fertilizer production requires a large amount of heat from fuel combustion. In traditional blast furnace operation, hot gases tend to flow along the furnace walls rather than distributing deeply into the central area. This reduces fuel efficiency and increases heat loss through the furnace walls.

Based on operational experience, the engineering team at Ninh Binh Phosphate Fertilizer has redesigned the furnace structure to provide better control of the gas flow. The tuyère openings have been repositioned further inside the furnace, set at a distance from the inner wall equivalent to 2%–20% of the furnace diameter. This arrangement increases the amount of air directed towards the centre, minimises hot gas movement along the walls, improves furnace operation, and ensures more efficient coal combustion.

Alongside adjustments to the tuyère system, the furnace shell has also been improved. The exterior is protected by a steel layer, while the interior is lined with high-temperature, fire-resistant material. The refractory bricks in direct contact with raw materials at high temperatures help limit heat transfer to the outside and protect the steel shell. The furnace operating procedures have also been revised to align with the improved structure.

Benefits of Technological Improvement

Once implemented, the solution improved furnace efficiency, enhanced phosphorus conversion, and controlled fuel consumption. More efficient fuel use reduces raw material costs and increases production effectiveness.

The solution also brings positive environmental and occupational safety outcomes. More efficient combustion lowers emissions, while the inner refractory lining reduces the surface temperature of the furnace shell, creating better working conditions for operators—especially those working at the furnace door.

The “Blast Furnace Innovation for Fused Phosphate Fertilizer Production” initiative demonstrates the effectiveness of starting from real production needs to research, adjust equipment, and refine technological processes. It is one of several measures by Ninh Binh Phosphate Fertilizer to save energy, reduce production costs, and promote greener, safer production.