ERDEMIR, which began production in 1965, today has a production capacity of 3.0 million tons/year of crude steel. It is the largest iron-steel company in Turkey and the only integrated flat steel producer. It produces plates, hot and cold rolled sheet and tinplate, all to international quality standards. ERDEMIR meets approximately half of Turkey's entire demand for flat steel and its products constitute the basic inputs for many different sectors in manufacturing industry, such as the automotive, pipes, white goods, pressurized containers and machinery. It also exports to a large number of countries, primarily to EU, U.S.A. and Japan. No.2 Blast Furnace (Zubeyde) is Erdemir's largest blast furnace. The first campaign of the No.2 Blast Furnace was started by blow-in operation on September 11,1978. Second campaign lasted approximately 12 years with a mid-campaign in 1995 and total hot metal production was 14,2 million tons. At February 27 ,1996 after two big slipping, channeling happened and the huge amount of semi melt materials stick the walls where the plates burnt. This block covered more than 1/3 of working volume of stack. This block tried to get rid off by effect of wall gas flow. As it is expected, after the Pulverized Coal Injection amount increased the heat load on the bosh region increased to considerably high values. Because of increased heat load and insufficient cooling at bosh section some hot spots and shell cracks were observed at the top of bosh shell just beneath the mantle region after 2 years from the mid-campaign. Some shell cracks were almost 2 meters long. Original structure of bosh region had a cylindrical shell and carbon refractory with water spray cooling system. After the detailed inspections, it was shown that lots of the carbon refractory was lost from the upper bosh near to mantle region. To keep furnace in operation until the next planned reline in 2000, two rows of cigar cooler were installed at the upper bosh and also carbon refractory injection was applied regularly inside the furnace. During these repairs in 1998, a reline team was assembled, consisted of personnel from engineering, blast furnace and refractory divisions to develop a feasible solution. Some important properties of No.2 Blast Furnace are given in Table.1.
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