Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. Two large blast furnaces that began their operation in 2009 and 2011 respectively. Blast furnaces are used to produce pig iron from iron ore for subsequent. It is crafted by arranging blast bricks into a solid 3x3x3 and rightclicking on the center block of any face with an engineers hammer. Ca2215406c method and apparatus for using blastfurnace. The method used in blast furnaces have been used since the 1500s. Blast furnace an introduction blast furnace is the focus of any integrated steel plant. The ore part of a charge consists of iron ores and concentrates, manganese ores and various types of scrap containing iron. Some examples of ferrous metals would be mild steel, cast iron, high strength steel, and tool steels. Hot blast stoves are very important auxiliary equipment to the bf process, providing hot blast to the process.
A blast of air contained within the blast furnace itself helps to intensify the degree of heat, expediting the smelting process. Blast furnace, a vertical shaft furnace that produces liquid metals by the reaction of a flow of air introduced under pressure into the bottom of the furnace with a mixture of metallic ore, coke, and flux fed into the top. The charge, which consists of iron ore, coke and limestone etc. Cognizant that the raw materials used in ironmaking are granular bodies, tanaka et al. Calculation of blast furnace size is empirical in nature. Blasts furnaces are used for smelting during the production of metals such as iron, lead, zinc, and copper. Blast furnace process an overview sciencedirect topics.
The blast furnace module is part of the steel manufacturing course. Using coal coke immersive engineering for fuel, it converts iron ingots and blocks into steel. In the second row, there should be 1 iron ingot in the first box, 1 furnace in the second box, and 1 iron ingot in the third box. The blast furnace uses iron ore as the ironbearing raw materials, coke and pulverised coal as reducing agents and lime or limestone as fluxing agents.
Iron oxides can come to the blast furnace plant in the form of raw ore, pellets or sinter. Research institute of mineral dressing and metallurgy. A process design for making ferrocoke from low grade non coking coal and iron ore fines as a chargematerial for blast furnace national institute of technology rourkela rourkela 769008, odisha, india. The venting of the blast furnace can be heard continually throughout the tapping process. Chemistry of the ironmaking by blast furnace process. Media in category drawings of blast furnaces the following 127 files are in this category, out of 127 total. Practices and design for extending the hearth life in the mittal steel company blast furnaces k. When making a blast furnace, it is important that the iron ingot, furnace and smooth stone are placed in the exact pattern as the image below. The energy in the furnace gas has been lost in the conventional wetprocess dust collector as the. The crude blast furnace formerly named blast furnace is a multiblock structure added by immersive engineering.
But do you know the metals are extracted from their ores using a process called smelting which is done in a furnace called as blast furnace. Describes the principles of the blast furnace process and especially the control of the process. The blowingin process is carried out in several steps fig 1 which consist of i drying out the lining, ii filling of the blast furnace with a specially arranged high coke blowin furnace. The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and preheated air is blown into the bottom. The blast furnace is a hightemperature, pressurized countercurrent reactor with dynamic process conditions. Mercury in blast furnace sludge universitat zu koln. Owater channel isolated stave gets hotter oeventually furnace shell gets hot and cracks occur nonfixed connection stave moves.
Products ironmaking and steelmaking modern blast furnace. Therefore, cooling stave life is a key parameter for the life of the blast furnace. They are then used to help heat the air blast, required if blast furnace is to reach the high temperatures needed to produce molten iron. List of new projects received during the year 201819 ii.
Larger lumps prolong the process of reduction and fluxing. For new turnkey installations of any capacity as well as for plant rebuilds, the modern blast furnace designs produced by paul wurth are based on the concept of a freestanding unit with a surrounding building structure, providing access to the furnace and support for the furnace offgas system. The process of blowingin of a blast furnace ispatguru. The biggest heat load thermal zone of the blast furnace is concentrated within the lower stave region of the blast furnace with intensified smelting. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. The production and development of the ironmaking process in china. Start studying chemistry steel making, redox, and organic chemistry. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally iron, but also others such as lead or copper. Proposed rule for mandatory reporting of greenhouse gases tons of air. Blast furnace is used to reduce the iron ore to iron. Optimization of blast furnace parameters using artificial. Bricks sic grout graphite grout page 16 pt is bf ternium blast furnace no. The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and preheated air is.
The iron in the processed ores must be dissolved out by chemical processes. Blast furnace gas has a high carbon monoxide co content and a low heating value, typical. Blast furnace charge raw materials for steelmaking. The production of iron and steel blast furnace process. Blast furnace sludge bfs was analyzed for mercury hg for the first time.
Chapter 11 iron and steel production flashcards quizlet. Process analysis for blast furnaces by the discrete. Our technology base covers the entire blast furnace process route from hot blast and raw material handling, through the furnace and casthouse, to gas cleaning and hot metal slag processing. Blast refers to the combustion air being forced or supplied above atmospheric pressure. Start studying chapter 11 iron and steel production. The main challenges in blast furnace ironmaking are currently related to lower coke rates, higher fuelinjection rates, high oxygen rates, high productivity and lowerquality raw materials of varying supply. Technological changes in blast furnace iron making in india since last few decades article pdf available in international journal of science and research ijsr 212.
The improved blast furnace is a multiblock machine added by immersive engineering. Learn vocabulary, terms, and more with flashcards, games, and other study tools. The efficiency of the process was further enhanced by the practice of. Technical support document for the iron and steel sector. This is to certify that the thesis entitled, study of blast furnace stave cooler based on heat transfer analysis submitted by prashant kumar azad in partial fulfillment of the requirement for the award of the degree of master of technology degree in mechanical engineering with specialization in thermal engineering at. The blast furnace process has auxiliary equipment associated with it. May 07, 2011 how a blast furnace works the purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. Mar 20, 2017 shows how iron ore, limestone, and coke are handled and prepared for the blast furnace in the making of iron. Blast furnace iron making is the main method for modern steel production,the process of blast furnace is an important part. The following is a list of links to pages that share the same title or have similar meanings. Chemistry steel making, redox, and organic chemistry. Smallvolume blastfurnaces the future of blastfurnace. Failure analysis for blast furnace using what if analysis. Ferrous comes from, or contains iron, while nonferrous does not contain iron.
Blast furnace is the metallurgical furnace used for smelting iron and steel using coal or coke as fuel. View and download ussc hotblast 57m owners manual online. Preheated air was first used by james beaumont neilson in 1828 in glasgow, but not until 1860 did the englishman. The energy in blast furnace gas in the forms of pressure and temperature is recovered by a trt generator after passing through the dust collector. How steel is made using the basic oxygen steelmaking process.
Furthermore there were numerous research works on the new technology of cupola furnaces smelting by using oxygen enriched blast, and obtaining pig iron from various. A blast furnace charge consists of ore, fluxes and fuel. Blast furnace gas blast furnace gas is a byproduct of blast furnaces where iron ore is reduced with coke into metallic pig iron. The vessel is internally lined with cooling elements and refractory bricks and blocks. Blast furnace process complexity in combination with growing demand on effectiveness. Iron making blast furnace consists of several zones a crucible shaped hearth at the bottom of the furnace, an intermediate zone bosh between hearth and stack. Cooling stave is one of the most important reasons that bring in major repair and maintenance of a blast furnace. In appearance, the typical blast furnace is in the form of a tower.
High performance control of blast furnace bf ironmaking process is a difficult problem due to the high temperature and hostile measurement conditions for measuring devices in the process. This is exactly what carbon can do as a reducing agent. With design, manufacture and installation of pig iron, ferromanganese smelting blast furnace, sinter plant, hot air stove, cip system, shaft furnace, lime kiln, etc. Modern cupola furnaces with hot blast produce about 100 thour i. The function of the hot blast stove is to provide hightemperature blast to the bf at a constant flow, which provides thermal energy and reducing gas to the bf process through the combustion of coke and injected fuels in the tuyere level. The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal.
Hotblast stove, apparatus for preheating air blown into a blast furnace, an important step in raising the efficiency of iron processing. Study of blast furnace stave cooler based on heat transfer. Below is a picture that displays a simplified version of the bos process. Many translated example sentences containing oxygen blast furnace.
A process and apparatus by which crushed and screened blast furnace slag 80 can be added to the feedstock materials 76 fed into the feedend of a rotary cement kiln to form cement clinkers 82. Blast furnace gas is produced during the iron oxide reduction in blast furnace iron making in which iron ore, coke and limestone are heated and melted in a blast furnace and is an indigenous process gas of the steelworks industry pugh et al. When the tapping takes place the drill can be heard clearly. Why does iron have to be extracted in a blast furnace iron can be extracted by the blast furnace because it can be displaced by carbon. Liquid iron hot metal is produced in a blast furnace from the burden materials through a series of chemical reactions which are taking place at various levels in a blast furnace.
It is the upgraded tier of the crude blast furnace unlike the crude blast furnace, the improved blast furnace will automatically export steel and slag immersive engineering to. Blast furnace met michelle henningerainscough then michelle henninger way back in 1990 at state college, pennsylvania, while she was a senior at the pennsylvania state university psu. Ofurnace dust enters between gasket and furnace shell and into compensators ocompensator fills with dust and locks stave movements oweld of pipe to stave body fails in fatigue owater leaks into furnace. Optimization of steelmaking using fastmet direct reduced iron. Primetals technologies has provided blast furnace engineering, project excellence and expertise to customers worldwide for over a century. Process analysis for blast furnaces by the discrete element method flows1. The most common primary production route is based on the blast furnace bf in combination. As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. Improved blast furnace official feed the beast wiki.
The refining of iron to make steel is where the carbon content of hot metal is. Blast furnace products and there use size of blast furnace design of blast furnace is evolved through experience. Blast furnace is the heart of the steel industry as it produces molten pig iron which is the raw material for steel making. The blast furnace slag is crushed and screened to provide blast furnace slag particles having particles with a size of up to a maximum diameter of substantially 2 or less. Now there are nearly 700 blast furnace available in world. Nowadays, the integrated steel making industry has put a lot of effort into finding. It is very important to minimise the operational cost, reduce fuel consumption, and optimise the overall efficiency of. Coal formation, mining, beneficiation coal quality coal blending coal to coke transformation coke. While receiving a redstone signal, the induction furnace will build heat passively, even when not smelting anything. Technoeconomic evaluation of innovative steel production. Recent developments in blast furnace ironmaking technology. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper. The induction furnace s internal battery can hold 10,000 eu.
Coke is a solid material, consisting mainly of carbon. May cause mechanical irritation to skin and lung irritation. The blast furnace is a huge, steel stack lined with refractory brick. The carbon is fed to the blast furnace in the form of coke pyrolyzed coal from the coking plant. The resulting molten iron also referred to as hot metal still contains 44. Pdf impact of operational parameters on fuel consumption. Though many improvements are made in the furnace over the years, the basic operation of. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a fuel and reducing agent. A dryprocess dust collector for blast furnace is equipment for cleansing blast furnace gas. Air heated in the blast furnace stoves, is applied from the bottom of the. Start up and stand up in indian blast furnace iron making. Production of pig iron in a blast furnace 9 scheme of a blast furnace content.
Once a blast furnace is started it will continuously run for four to ten years with only short stops to perform planned maintenance. It is suitable for students of metallurgy as well as for blast furnace operators and management. The prime criterion for the commercial acceptance of new advanced melting technologies is that they must not be capital intensive for installation. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals. The burden charge consisting of iron oxide, flux and coke and it provides through the throat from the top of the furnace. A blast furnace works by blasting hot air up through the furnace while fuels, limestone, and ore move continuously through the top of the furnace. Pdf technological changes in blast furnace iron making. These materials must be in lumps of a certain size 4060 mm. Also, with my experience, i have tried to give a concept about the plant engineering related to raw material. Practices and design for extending the hearth life in the. In the 5th century bc the chinese used blast furnace. The formation of iron and steel the blast furnace 2.
The blast furnace operates as a countercurrent exchange process whereas a bloomery does. The metallic iron produced by such a furnace contains a relatively high proportion of carbon 4% and is passed to the steelmaking process as a liquid at approximately 1450c, called hot metal. R e f r a c t o r i e s f o r b l a s t f u r n a c erefractories for blast furnace 15 blast furnace shapes 65 mm tickness code description dimensions mm. Iron ore, coke and limestone are put into the top, and preheated air is blown into the bottom. Iron blast furnace is a vertical shaft, which is used to melt the iron ore and to produce hot metal by heat exchange and chemical reaction. Coal, which is crucial to the blast furnaceoxygen steel production process. The temperature in the blast furnace is as high as 1600 and constantly changing, making it difficult to maintain at a stable level. The bottom cylindrical part of the profile is called a hearth, wherein pig iron and slag. Iron oxides, flux agents, and metallurgical coke are added to a skip car at the stock house. Ironmaking, the first step, involves the raw inputs of iron ore, coke, and lime being melted in a blast furnace. Profile of a blast furnace and its dimensions are adapted to technology of process, see figure.
This requires an element that binds oxygen more strongly than iron. The volatile fraction consists of coking gas and coal tar. The smelting process in cupola furnace is also consid ered to be competitive. Secure doors are mounted onto the front of the device, making it possible to feed the raw materials into the furnace either by hand or with the use. Model development of a blast furnace stove sciencedirect. Step 2 the blast furnace the outer case is a water cooled steel casing that provides the main support for the 30 m high furnace. This is to certify that the project report entitled blast furnace, being submitted by suraj kumar vishwakarma of dit university to tata steel, as a part of summer training course of b. In a blast furnace, fuel coke, ores, and flux limestone are continuously supplied through.
Smaller lumps block the fluegas passages and prevent a uniform descent of melting materials in the furnace. Precautionary statements do not breathe dusts or fume. The blast furnace produces a total of,000 tons of pig iron a day. In this paper the potential of using direct reduced iron dri from the fastmet process with rotary hearth furnace rhf technology, as a partial substitute of pellets in a blast furnace bf was. If an internal link led you here, you may wish to change the link to point directly to the intended article. Oxygen furnace bof to create liquid steel, solidifying the liquid steel via continuous casting, and finally sending the semifinished casts to various finishing refinements. The raw ore is removed from the earth and sized into pieces that range from 0. Blast furnace ironmaking process using prereduced iron ore kazuya kunitomo1 yasushi takamoto 1 yasuhiko fujiwara2 takashi onuma3 abstract it may be possible to improve the productivity and flexibility of the blast furnace operation and also to substitute energy sources in the pig iron production processes. The iron ore concentrate is now mixed and ready for the pelletizing process. Inside the blast furnace bf the process is very complicated and very tough to model mathematically. This auxiliary equipment and the gaseous pathways inside a blast furnace process are shown in fig. The production of large blast furnaces during 2016 and future. Apr 03, 2010 dear readers, in this presentation, i have tried to explain main raw material sources of iron making process. The application of linux and database system for blast furnace.
Blast furnace blast furnace produces pig iron from iron ore by reducing action of a carbon at a high temperature in the presence of fluxing agent such as limestone. Basic oxygen furnace bof steel making or basic oxygen furnace steelmaking bos or linzdonawitzverfahren steelmaking or the oxygen converter process is a method in which both molten pig iron and steel scrap are converted into steel with the oxidizing action of oxygen blown into the melt under a basic slag. This module introduces the learner to the operation of the blast furnace for the transformation of iron ore to molten iron. There are three routes to achieve this production target integrated steel plant with large blast furnace, installation of mini blast furnaces and upgradation of existing blast furnaces. Plant and equipment, metallurgical processes, chemistry, raw materials, products and byproducts, operation, alternative. At that time, she may not have imagined that one day, shed be sketching and painting artwork for inclusion in books for young children. Donald wagner suggests that early blast furnace and cast iron production evolved from. The chapter first gives information about fundamentals and historical development of bf technology and design and its role in the steel. This article is a disambiguation page for bronze blast furnace. Jan 28, 2016 the blast furnace is a huge, steel stack lined with refractory brick.
It is partly due to the complexity of the whole process and partly the extreme temperature. This book focuses on the control of the blast furnace process with respect to thermal control, gas flow control and casthouse operation. Blast furnace, coke gas and converter gas for power production. Furnace process and position of cohesive zone high rates of injection productivity. Pelletizing a pellet plant contains a series of balling drums where the iron ore concentrate is formed into soft pellets, in much the same manner that one rolls a snowball, to make a pellet about the size of a marble between 14 and 12. The main objective of blast furnace ironmaking is to produce hot metal with consistent quality for the bos steelmaking process. Impact of operational parameters on fuel consumption of a blast. Blast furnaces can generate in all villages variant armorer houses, usually under blocks of glazed terracotta. Subspace method for identification and control of blast. This chapter discusses the blast furnace bf iron making. Blast furnaces differ from bloomeries and reverberatory furnaces in that in a blast furnace, flue gas is in direct contact with the ore and iron, allowing carbon monoxide to diffuse into the ore and reduce the iron oxide to elemental iron mixed with carbon.
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