As a starting point, the blast furnace is seen as a simple iron ore smelter, while gradually the physical, chemical and metallurgical background of the blast furnace process is clarified. The blast furnace at saugus features a fieldstone chimney stack that stands 21ft. Ironmaking blast furnaces consist of several zones. Blast refers to the combustion air being forced or supplied above atmospheric pressure in a blast furnace, fuel, ores, and flux limestone are continuously supplied through the top of the furnace, while a hot blast of air. Im new to the blast furnace and would love some advice from you guys. Blast furnace economics are such that larger units have lower unit production costs, hence there has been a trend to bigger and bigger furnaces. Describes the principles of the blast furnace process and especially the control of the process. Iron is made by reacting iron ore iron oxide and impurities, coke a reductant and limestone caco 3 in a blast furnace iron ores with lower iron content such as taconite are first processed to concentrate the iron level and drive off volatile impurities.
The rated capacity of this furnace is 9,500 tons of hot metal per day with pulverized coal injection system of 200 kgthm. Learn more who are renowned for creating steel using a blast furnace process and very short step from the blast furnace. These aggregates increased the productivity and therefore proved the economic benefit of the blastfurnace. Process monitoring of ironmaking process in a blast furnace. Modern blast furnaces produce more than 10,000 tonnes per day. Since then many other alternative processes of iron making have arisen e. Mar 06, 2016 introduction and construction blast furnace.
This book discusses the importance of blast furnace process as a complete operation. Blast furnaces produce pig iron from iron ore by the reducing action of carbon supplied as coke at a high temperature in the presence of a fluxing agent such as limestone. It is suitable for students of metallurgy as well as for blast furnace operators and management. The blast furnace ironmaking process had, until recently, been the unchallenged method of making hot metal on a large scale. Several companies in the region have announced that they are going to construct their first blast furnace. Modern furnaces are highly efficient, including cowper stoves to preheat the blast air and employ recovery systems to extract the heat from the hot gases exiting the furnace. The ussr was the world leader in largevolume blast furnace manufacture. Specific coke or fuel consumption equivalent coke rate. A study of the heat flow in the blast furnace hearth. All the three ingredients are crushed into small round pieces and mixed and put on a hopper which controls the input. Iron comes out fro m the blast furnace at the lo wer level through a notc h, called iro n notch, while t he slag is elimi nated from the blast furnace through a different notch, called the slag. This section deals with the types of iron and steel which are produced as a result of the steel making process. So i decided to build this small portable cupola furnace to do just that.
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. In fact, they are basically the forerunner to modern conventional last blast furnaces and hence they have operated for a longer. Flow sheet of iron making raw materials for blast furnace iron making iron ore for bf ahaematite fe203,magnetite fe304. Cast iron was made by smelting iron ore with charcoal fuel in the blast furnace, where it. The intensive utilization of fossil carbon in the ironmaking blast furnace bf is related directly to. Extraction of iron metallurgy blast furnace and reactions.
Theory and practice presents theoretical, experimental, and operational evidence about the iron blast furnace as well as a mathematical description of its operation. During tapping, complicated processes take place in which e. Now there are nearly 700 blast furnace available in world. Guidance for the production of coke, iron and steel sepa. Ironmaking 101 from ore to iron with blast furnaces. Silicon and aluminum often occur in iron ores as quartz, aluminum silicate clay minerals, or gibbsite. Blast furnace hot metal and recycled steel in the form of scrap have been the main sources of iron.
Blast refers to the combustion air being forced or supplied above atmospheric pressure. Iron and steel making is one of the most intense energy consuming in the industrial sectors. Request pdf on aug 1, 2016, liu xiong and others published constructal design of a. In addition to raw materials iron ore and coke quality. The principal function of a blast furnace is to continuously produce liquid hot metal viz. The blast furnace at saugus iron works national historic site. 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. The restoration of an iron making blast furnace automation system is a stimul ating challenge that involves process, electrical and automation competences and that. After mining, various kinds of iron ores are brought to the blast furnace which is the starting process for refining iron ores or mined ores and for the production of pig iron. This is very bad behavior for a material being put into an ironmaking blast furnace, becaus. Pdf technological changes in blast furnace iron making. The lower part of an iron making blast furnace, the hearth, consists of a packed bed of coke particles through which liquid hot metal flows during tapping.
And even bronze can fail to fulfil an inner melting need. The method used in blast furnaces have been used since the 1500s. In the latter half of the past century blast furnaces with the working volume of 86, 15, 1719, 2002, 2300, 2700, 3200, 5014, 5580 m3 were manu factured. The coke is removed from the wharf by manual gates or a plough coke. Two large blast furnaces that began their operation in 2009 and 2011 respectively.
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 blast furnace is a huge, steel stack lined with refractory brick. Primetals technologies has provided blast furnace engineering, project excellence and expertise to customers worldwide for over a century. Mini blast furnaces mbf are generally viewed as miniature versions of the conventional large blast furnaces bf. A wooden charging bridge extends from a bluff to a charging hole at the top of the chimney stack. All students, freshers can attemp or download metallurgical engineering physical metallurgy quiz questions with answers as pdf files and ebooks. With its breakthrough developments in both blast furnace iron making and bof steelmaking indian steel producers both in public and private sectors have been leveraging the benefits in both greenfield and brownfield situations. Once a blast furnace is started it will continuously run for four to ten years with only short stops to perform planned maintenance. Simulated blast furnace reduction of acid pellets in the temperature range 95050c. Wrought iron is quite soft and easily worked and has. Please practice handwashing and social distancing, and check out our resources for adapting to these times. Modern blast furnaces produce more than 10,000 tonnes per. These furnaces are ideally suited for small scale operations.
After awhile a guy like me get tired of just melting aluminum. Pdf technological changes in blast furnace iron making in. This is because though although the blast furnace process has a long history. The blast furnace 9 the structure of the blast furnace 9 the iron making process 11 no. Till 1990, the blast furnace route of ironmaking had about 97% 527mt share of global iron production. 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.
In addition, no sinter and therefore no sinter plant is necessary for optimal operation. For general information about merchant pig iron, please visit the pig iron page. 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. So it was only a matter of time before i set out to melt iron. As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. The purpose of a blast furnace is to reduce and convert iron oxides into liquid iron called hot metal. In lecture 31 a simplified material balance is considered for ironmaking blast furnace and the results of material balance formulation are presented in the form rist diagram in that it is considered that charge consists of pure iron oxide and coke and the product is hot metal containing carbon only. The physicochemical fundamental concepts of chemical equilibrium, activitycomposition relationships, and. It was the smelting unit where raw materials were transformed into molten iron.
Iron is made by reacting iron ore iron oxide and impurities, coke a reductant and limestone caco 3 in a blast furnace. The typical iron oxide mix for corex is 30% lump ore and 70% pellets. Modern cupola furnaces with hot blast produce about 100 thour i. Step 2a the blast furnace the sinter is added through a hopper at the top of the blast furnace. 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. Blast furnace ironmaking process is an energy intensive and resource. Electric arc furnace steelmaking continuous casting. Blast furnace iron making is the main method for modern steel production,the process of blast furnace is an important part. Blasts furnaces are used for smelting during the production of metals such as iron, lead, zinc, and copper. With design, manufacture and installation of pig iron, ferromanganese smelting blast furnace, sinter plant, hot air stove, cip system, shaft furnace, lime kiln, etc.
This project has been performed to increase the steel making production capacity of esfahan steel company in iran from 2. The smelting process in cupola furnace is also consid ered to be competitive. Pig iron and refined iron ore pellets briquetted iron can also be used, and because his t method is economic at lower volumes these operations are called mini mills. The blast furnace is an ironmaking process with a long history. The energy consumption in blast furnace is affected by many factors controlling its productivity. The lessons are there for the steelmaking industry both in the uk. Conceptual division of the blast furnace bottom segment calculations 8. The iron ore concentrate is now mixed and ready for the pelletizing process. It begins by tracing the history of iron and steel production, right from the earlier days to todays world of oxygen steelmaking, electric steelmaking, secondary steelmaking and continuous casting. Blast furnace basic oxygen furnace uses iron ore as its base raw material that accounts over just 50% of bof steel costs, and electric arc furnace uses scrap as its base that represents around 75% of eaf steel cost. The formation of iron and steel the blast furnace 2. A typical blast furnace along with its various parts is shown in fig. 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. This authoritative account covers the entire spectrum from iron ore to finished steel.
Plants that use electric arc furnaces can be sited closer to the market. Blast furnace smelting equipment sinter plant lime kiln. Report on the explosion at corus uk ltd 8 november 2001 hse. The ascending gases start to reduce the iron oxide of the burden in the upper portion of the blast furnace where the temperature is below 925 deg c. This book describes the principles of the blast furnace process and especially the control of the process. The making of iron with animations and diagrams duration. 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. Where market size permits, some degree of product specialisation is practised. The principle of blast furnace operational technology and. The blast furnace remains an important part of modern iron production.
In a blast furnace, fuel coke, ores, and flux limestone. Calculation of blast furnace size is empirical in nature. Cast iron is more brittle than wrought iron or steel, which required additional fining and then cementation or cofusion to produce, but for menial activities such as farming it sufficed. The hot spot phenomenon in basic oxygen furnace bof process. A blast furnace is a gigantic, steel stack lined with refractory brick where the concentrated iron ore, coke, and limestone are dumped from the top, and a blast of hot air is blown into the bottom.
Major impurity elements in iron ore that can affect the quality of iron produced in a blast furnace and the efficiency of blast furnace ironmaking are silicon, aluminum, phosphorus, and sulfur. India as a 4th steel producer in the world has resulted due to adaptation of new technologies in the field of iron and steel making since from the last few decades. Production of pig iron in a blast furnace chapter division basic terms description of a blast furnace plant main parts of a blast furnace, description and function composition of a charge in the production of pig iron in a blast furnace. Direct reduction scrap ladle refining electric arc furnace steelmaking iron ore pellets. Smallvolume blastfurnaces the future of blastfurnace. Salzgitter the process shown above is illustrative only and is not designed to show the steelmaking process in detail. The iron ore, pellets and sinter then become the liquid iron produced in the blast furnace with any of their remaining impurities going to the liquid slag. This book includes a set of equations that accurately describe stoichiometric and enthalpy balances for the process and which are consistent with observed. Design of blast furnace is evolved through experience. This furnace will be the indias largest blast furnace to date. How pig iron is converted into iron and steel in blast. Oct 26, 2010 ironmaking in blast furnaces 0 200 400 600 800 1200 1400 1600 30 20 10 0 5 fe 2 o 3 scrap hot metal refining liquid steel direct molten steelmaking blast furnace and smelting reduction direct reduction remelting dri, hbi o x y g e n % c a r b o n % temperature o c iron ore scrap iron ore to liquid steel blast furnace ironmaking amongst all the ironmaking. Cast iron staves in the hearth, upper stack and throat five rows of copper staves are installed in the high heat flux zones of the bosh, belly and lower stack a new blast furnace shell means the use of the standard.
Operational results proved stable operations with a lump ore fraction up to 80%. Biomass, pig iron, ironmaking, carbon footprint assessment, life cycle assessment, resource, coal, coke, blast furnace. The basic oxygen steelmaking process differs from the eaf is that bof is selfsufficient in energy. Blast furnace ironmaking an overview sciencedirect topics. This furnace is designed for a twenty year campaign. In the experimental study, manual measurements were carried out on the outer surfaces of the furnace. Blast furnace iron making raw materials blast furnace reaction. Using biomass for pig iron production archive ouverte hal.
Iron oxides can come to the blast furnace plant in the form of raw ore, pellets or sinter. The world leader in ironmaking solutions primetals technologies. Iron ores with lower iron content such as taconite are first processed to concentrate the iron level and drive off volatile impurities. Introduction to the blast furnace enthalpy balance 6. New developments in iron making process iron units in various forms are required for making steel. Introduction kobe steel started operation as an integrated steel manufacturing company with the blowingin of the no. The performance of ironmaking blast furnace can be characterized in different ways. Chemistry of the ironmaking by blast furnace process.
Keeping in view for increasing quality of hot metal and its production rate. Theory and practice presents the significant role of iron blast furnace by which iron is efficiently and rapidly reduced from ore and it is the basis for all primary steelmaking. A preheated air is blasted into the furnace and after a series of reaction, molten pig iron is produced. Its process of production, wootz steel, was exported before the 4th century bc from india to ancient china, africa, the middle east and europe. The raw ore is removed from the earth and sized into pieces that range from 0. 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. At this temperature, chemical equilibrium prevents all the co and h2 fro being used for reduction the equilibrium coco2 ratio is around 2. The blast furnace appeared in europe in the 15th century when it was realized that cast iron could be used to make onepiece guns with good pressureretaining properties, but whether its introduction was due to chinese influence or was an independent development is unknown. By malik mubashir university of the punjab lahore, pakistan 2. It is the volume of blast furnace occupied by the charge materials and the products, i. The softening and melting of blast furnace burden materials. This book focuses on the control of the blast furnace process with respect to thermal control, gas flow control and casthouse operation. The iron blast furnace is a large, tall, vertical metallurgical furnace used for reducing molten iron from its oxide ores and is one of the major reactors in the iron making industry. Mar 08, 2014 this feature is not available right now.
Bof process has been used in steelmaking process because of its high. Steel with a carbon content between pig iron and wrought iron was first produced in antiquity as an alloy. If all the carbon is removed from the iron to give high purity iron, it is known as wrought iron. The primary advantage of the early blast furnace was in large scale production and making iron implements more readily available to peasants. T, burla person involved name designation and email.
Mini blast furnace blast furnace is the most popular route to produce molten iron for steel making. Competition in industry drives higher production rates. An analysis of hot spot phenomenon in bof process request pdf. In the furnace hot metal, along with slag is processed from the raw material which gets collected in the hearth and blast furnace gases come out of blast furnace from the top. Danieli corus has enjoyed an incredible journey with indian steel industry over the years. The gases co, co2,and n2 leave the furnace through the top. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing.