Iron making solutions to extend blast furnace lifetime. The rated capacity of this furnace is 9,500 tons of hot metal per day with pulverized coal injection system of 200 kgthm. Minerals and ironmaking reactions in blast furnaces. The majority of pig iron produced by blast furnaces undergoes further processing to reduce the carbon content and produce various grades of steel used for tools and construction materials. 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.
A potent symbol of a steelworks, blast furnace is a facility to produce hot metal by smelting iron ore. Please practice handwashing and social distancing, and check out our resources for adapting to these times. Iron making deals with the extraction of iron from ores because iron without processing is only available in meteorites. Finally i needed a furnace that could reach 3000f so i could pour brass and iron. This book focuses on the control of the blast furnace process with respect to thermal control, gas flow control and casthouse operation. To develop computational and mathematical abilities to be applied for process design and control. The basic idea involves the heating of an iron oxide, often haematite, fe 2 o 3, with carbon. Steel making converts molten iron into steel which is much more useful. Where a cooling tower exists, our cooling fans are an important way to remove heat. Extraction of iron metallurgy blast furnace and reactions. Iron and steel industries consumes enormous amount of energy and contributes significantly in carbon dioxide emission. A jet of air is used to burn the carbon to form the gas carbon dioxide. Iron making blast furnace iron making blast furnaces. The typical iron oxide mix for corex is 30% lump ore and 70% pellets.
Danieli corus has enjoyed an incredible journey with indian steel industry over the years. Blast furnace fans are essential to drive heated air into the furnace and our id fans are then used to draw the furnace gases. The production of iron in a blast furnace is an important industrial process, although other methods for iron production are also in use. 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 section deals with the types of iron and steel which are produced as a result of the steel making process. For the hotter metals like nibral at 2300f to iron at 3000f must use a clay or silicon carbide crucible. Thereby iron production is divided into two stages.
The calcium silicate melts and runs down through the furnace to form a layer on top of the molten iron. With design, manufacture and installation of pig iron, ferromanganese smelting blast furnace, sinter plant, hot air stove, cip system, shaft furnace, lime kiln, etc. The process injects oxygen through the molten iron removing most of the. Mini blast furnace mbf is the most proven technology, as revealed by one recent global iron production data. The melt was carburized and the manufactured iron ceased to be malleable. Blast furnaces are also called high ovens a blast furnace is usually built with a steel case and bricks made of magnesia inside the case. The economics of iron production along with the appropriate technology underwent several changes in the past.
Aug 03, 2011 the calcium silicate melts and runs down through the furnace to form a layer on top of the molten iron. Blast furnace smelting equipment sinter plant lime kiln. Describes the principles of the blast furnace process and especially the control of the process. It is suitable for students of metallurgy as well as. Once a blast furnace is started it will continuously run for four to ten years with only short stops to perform planned maintenance. The limitation on the recycle of steelmaking slag to the iron blast furnace is typically the impurity content, particularly the sulfur, phosphorus, and zinc. The principle of blast furnace operational technology and. The pig iron produced by the blast furnace has a relatively high carbon content of around 45%, making it very brittle, and of little commercial use. The haematite reacts with carbon in the cast iron to give pure iron and carbon monoxide gas which escapes. 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 most common ore of iron is called haematite ironiii oxide. Snclavalin specializes in epcm for all phases of the iron and steel making processes including providing services for coke plants, blast furnaces, casters, industrial furnaces, rolling mills, finishing and coating lines, air pollution control, water pollution control, chemical processing, and bulk material handling systems. Step 2a the blast furnace the sinter is added through a hopper at the top of the blast furnace. Installation of big blast furnaces not only requires huge capital but the. The nonuniform flow, heat transfer, and carbon dissolution from the refractory and the coke bed dead man cause large differences in thermal conditions and hot metal composition. The formation of iron and steel the blast furnace 2. The iron is eliminated from the blast furnace as a special metallic material called pig i ron, with a high level of carb on and impurities in its compositio n. This furnace is designed for a twenty year campaign.
The blast furnace has charging arrangements at the top and means of running off the pig iron and slag at the. Ironmaking 101 from ore to iron with blast furnaces. The raw ore is removed from the earth and sized into pieces that range from 0. This furnace will be the indias largest blast furnace to date.
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. Extraction of iron in a blast furnace iron is also below carbon in the reactivity series, so therefore carbon can be used to reduce it note. Be able to understand basic layout of blast furnace, steelmaking shop and continuous casting process. Introduction kobe steel started operation as an integrated steel manufacturing company with the blowingin of the no. Creating steel from lowgrade iron ore requires a long process of mining, crushing.
Valia, scientist, ispat inland inc introduction a world class blast furnace operation demands the highest quality of raw materials, operation, and operators. Molten iron ore is tapped at the bottom of the blast furnace, poured into the iron ladle and removed for use. Foundry work was a minor branch of the industry, but darbys son built a new furnace at nearby horsehay, and began to supply the owners of finery forges with coke pig iron for the production of bar iron. 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. This section deals with the types of iron and steel which are produced as a result of the steelmaking process. The authors have very extensive experience as operators as well as consultants to many steel plants worldwide. Kinetics and modeling of ironmaking blast furnace overview the ironmaking blast furnace is a complex multiphase flow reactor. The structure of pig iron blast furnace is made of steel plate and refractory bricks,and its shape is vertical drum like bowling pin. Electric furnaces for making iron and steel page 63 unt.
Mar 20, 2017 shows how iron ore, limestone, and coke are handled and prepared for the blast furnace in the making of iron. An interesting representative of such processes is the blast furnace iron making process 1 2 3, which uses multisensors such as two manual measurements and two infrared acquisitions to. Today the strategy of the ironmakers is to extend the campaign life of blast furnace as much as possible so that the total relining is required at least after 14 15 yrs of operation. Blast refers to the combustion air being forced or supplied above atmospheric pressure in a blast furnace, fuel, ores, and flux are continuously supplied through the top of the furnace, while a hot blast of air sometimes with. The iron that comes out of the blast furnace if allowed to cool is called cast iron or pig iron it is very impure containing about 4% carbon. Geologists recognise various types of iron ore, classified chiefly according to iron fe content see table 1 below. Slag is used in road making and as slag cement a final ground slag which can be used in cement, often mixed with portland cement. An interesting representative of such processes is the blast furnace ironmaking process 1 2 3, which uses multisensors such as two manual measurements and two infrared acquisitions to. Coke production for blast furnace ironmaking by hardarshan s. Blast furnace ironmaking an overview sciencedirect topics. Pdf technological changes in blast furnace iron making. Wrought iron is the purest form of iron available commercially available and is prepared from cast iron by heating cast iron in a furnace lined with haematite fe2o3. In addition, no sinter and therefore no sinter plant is necessary for optimal operation.
In fact it is believed that iron makes up about 5% by weight of the earths crust. With modern blast furnace ironmaking an introduction the reader has a compact compendium of the blast furnace process available. The iron ore concentrate is now mixed and ready for the pelletizing process. Iron ore processing for the blast furnace courtesy of the national steel pellet company the following describes operations at the national steel pellet company, an iron ore mining and processing facility located on the mesabi iron range of minnesota. Operational results proved stable operations with a lump ore fraction up to 80%. Ironmaking and steelmaking metallurgical and materials. For example, at a large ironworks with an output of 7 million tons of raw steel a year, around 570 million tons a year of converter gas is generated, which is the equivalent of m 3. Use of pure oxygen while blast furnace operators aim to enrich the hot blast.
All the three ingredients are crushed into small round pieces and mixed and put on a hopper which controls the input. Blasts furnaces are used for smelting during the production of metals such as iron, lead, zinc, and copper. Iron oxides can come to the blast furnace plant in the form of raw ore, pellets or sinter. The pig iron blast furnace provides the means by which iron is rapidly and efficiently reduced from iron ore and it is the basis for all primary steelmaking. Kinetics and modeling of iron making blast furnace overview the iron making blast furnace is a complex multiphase flow reactor. Coke iron was initially only used for foundry work, making pots and other cast iron goods.
We demonstrated our enormous capabilities for providing largescale blast furnaces by construction of no. The most common ore of iron is called haematite iron iii oxide. The blast furnace is a fundamentally vertical shaft varying in height from 24 to 33 meters with the diameter at the hearth of about 8. Recent developments in blast furnace ironmaking technology. Although there are various iron making processes, the mini blast furnace route is the most preferred in the modern day scenario. While gasbased as well as coalbased dri production routes produced 2. They can be up to 60 metres 200 ft tall and 15 metres 49 ft in diameter. Blast furnace iron making is the main method for modern steel production,the process of blast furnace is an important part. Ironmaking plant is an integral part of any steelworks which. Pdf technological changes in blast furnace iron making in. In the furnace, coke supplies heat energy while physically maintaining the permeability of the blast furnace bed. This project has been performed to increase the steel making production capacity of esfahan steel company in iran from 2.
It is suitable for students of metallurgy as well as for blast furnace operators and management. Coke is the most important raw material fed into the blast furnace in terms of its effect on blast furnace operation and hot metal. 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. The second most important after blast furnace gas source of carbon monoxide at iron and steel companies is converter gas 32. The transport phenomena and physical status in the hearth of an iron making blast furnace are very complicated and difficult to monitor and characterise. Shows how iron ore, limestone, and coke are handled and prepared for the blast furnace in the making of iron. 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 cannot operate without coke, but since it is the most expensive feed material used in the blast furnace ironmaking process, there has always been a demand to minimize its use. Molten iron ore is tapped at the bottom of the blast furnace, poured into the iron ladle and.
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