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. Coke production for blast furnace ironmaking by hardarshan s. Fired by a highvolume propane feed with spark ignition. When we supply the raw material hematite, lime stone, coal continuosly through the top of the blast furnace. The production of iron from its ore involves an oxidationreduction reaction carried out in a blast furnace. This was a simple method used from the iron age to medieval times where iron ore and charcoal were placed in a small furnace. Since this coke and iron ore are stayed inside blast furnace layer by layer, coke and iron must sustain a certain amount of weight. Why use coke for blast furnace ironmaking not use coal directly coke is an important raw material in the smelting process of the blast furnace, accounting for about 45%. Chemistry of the ironmaking by blast furnace process. However, due to transit disruptions in some geographies, deliveries may be delayed. Extraction of iron in a blast furnace reduction haematite o. Based on the simulation tests of the four zones of smelting process in blast furnace at panzhihua iron and steel co, the differences in reduction, softeningmelting and dropping temperatures and.
T, burla person involved name designation and email. The authors have very extensive experience as operators as well as consultants to many steel plants worldwide. Blast furnaces are similar to furnaces, but can smelt only ore blocks and toolsarmor made of iron, gold or chainmail. Blast furnace iron making is the main method for modern steel production,the process of blast furnace is an important part. Modern blast furnace ironmaking anintroduction withcontributionsfrom renard. Conclusion within the content of this paper, we have hopefully taken the opportunity to highlight the status of the blast furnace as an advanced process that takes seriously its impact on the world. Ios press ebooks modern blast furnace ironmaking an. Modern blast furnace ironmaking 3rd edition pdf for free.
Pig iron is divided into steelmaking pig iron, which is intended for further processing to steel by various refining processes, and foundry pig iron, from which cast iron is produced by remelting. In the blast furnaces bf liquid iron popularly termed as hot metal is produced by the process of reduction at high temperature from raw materials like iron ore, base mix, sinter, pellet, coke, fluxes limestone, quartzite, dolomite. Blast furnace hot metal and recycled steel in the form of scrap have been the main sources of iron. Process monitoring of ironmaking process in a blast. It is mainly for use for iron castings, and for abrasion resistance and heattransfer applications. Ironmaking 101 from ore to iron with blast furnaces. Theory and practice presents theoretical, experimental, and operational evidence about the iron blast furnace as well as a mathematical description of its operation.
Mar 20, 2017 shows how iron ore, limestone, and coke are handled and prepared for the blast furnace in the making of iron. The blast furnace is a countercurrent gassolids reactor in which the descending column of burden materials coke, iron ore and fluxesadditives reacts with the ascending hot. This book focuses on the control of the blast furnace process with respect to thermal control, gas flow control and casthouse operation. Modeling of burden distribution in the blast furnace doria. For general information about merchant pig iron, please visit the pig iron page. Homemade tilting furnace utilized as a reverbatory to facilitate the recovery of precious metals from the refining process. 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. Composition of a charge in the production of pig iron in a blast furnace. Step 2a the blast furnace the sinter is added through a hopper at the top of the blast furnace. The purpose of a blast furnace is to reduce the concentrated ore chemically to its liquid metal state. Manufacture of iron by blast furnace process iron is a naturally occurring element in its ore form haematite, however for iron to be of any use the impurities must be removed. 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. They can be up to 60 metres 200 ft tall and 15 metres 49 ft in diameter. The furnace is heated constantly and is recharged with raw materials from the top while it is being tapped from the bottom.
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 bfbased ironmaking process accounts for more than. Incidents happening in the blast furnace will strongly affect the stability and smoothness of the iron making process. With its breakthrough developments in both blast furnace ironmaking and bof steelmaking indian steel producers both in public and private sectors have been leveraging the benefits in both greenfield and brownfield situations. 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 done by a process involving a blast furnace. Process monitoring of ironmaking process in a blast furnace. A variety of processes take place within the blast furnace, as the stock slowly moves downwards and temperatures increase. One of the iron making techniques spread by the romans as far north as great britain was the early bowl or shaft furnace. The production of iron in a blast furnace is a continuous process. Coke is the most important raw material fed into the blast. The principle of blast furnace operational technology and.
This book describes the principles of the blast furnace process and especially the control of the process. Manufacture of iron by blast furnace process 988 words. Impurities in the iron from the blast furnace include carbon, sulphur, phosphorus and silicon. Within the iron and steel industry, the ironmaking processes are acknowledged to be the focus area when the topic of energy saving arises. Process monitoring of ironmaking process in a blast furnace with pcabased methods article pdf available in control engineering practice 47. Pdf process monitoring of ironmaking process in a blast. Once an item and a fuel are placed into the blast furnace, the block state changes to lit and the item is smelted twice as fast as a regular furnace. Describes the principles of the blast furnace process and especially the control of the process. In this book, all essential process details are described and a special focus is on optimization of coal injection. Why use coke for blast furnace ironmaking not use coal. The iron making process developed around the mediterranean sea had spread northward through europe. Pdf blast furnace ironmaking a view on future developments.
Blast furnace ironmaking free download as powerpoint presentation. Environmental issues for the blast furnace process. The current stateoftheart practice is to granulate molten blast furnace slag in wet. Extremely high temperature in the range of 870c are reached within. Blast refers to the combustion air being forced or supplied above atmospheric pressure. Overview of the steelmaking process pellets sinter limestone coke iron ore coal scrap blast furnace ironmaking converter steelmaking ladle refining blast furnace steelmaking coalnatural gas plate hotrolled bars rods tube rounds rails slab billet bloom hotrolled and coldrolled strip coils structural shapes. Blast furnace ironmaking an overview sciencedirect topics.
The furnace here only requires half as much coal when smelting usually, so it can be useful when smelting the ores that require more coal there are 15 blast furnace worlds on old school runescape, all of which make soloing the blast furnace easy as there are five different dwarves dumpy, stumpy, pumpy. Casthouse floor design, furnace tapping equipment, hot metal tapping equipment for the ferrous and nonferrous industry. The formation of iron and steel the blast furnace 2. Efficient and environmentally friendly smelting reduction a vai ironmaking technology. Introduction of high quality coke to a blast furnace will. The reduced iron along with coal and lime is fed to a gasifiermelter, which completes the reduction process and produces pig iron or hot metal of the same quality as a blast furnace. Rdcis 2 emerging scenario in iron making more than 90% of world iron production is through blast furnace technology route.
Annual energy flow overview of the steelmaking process. In section 2, a brief description of the blast furnace process is glven. Milestones of our blast furnace operation technologies tamura categorized our history of pig iron making into the following three periods, in an article. Iron ores with lower iron content such as taconite are first processed to concentrate the iron level and drive off volatile impurities.
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 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 ironmaking industry. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace. It has been observed in the experimental blast furnace that the iron bearing materials do disintegrate at low temperatures under mildly reducing conditions, that is in the upper part of the stack, affecting the furnace permeability and consequently the output adversely. 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. 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. Ironmaking 101 from ore to iron with smelting and direct. Blast furnace iron has limited engineering applications. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. The following areas of the blast furnace process are currently the focus of. This book includes a set of equations that accurately describe stoichiometric and enthalpy balances for the process and which are consistent with observed. Iron making in the furnace usually continues for about ten years before the furnace linings have to be renewed.
Chapteri introduction oftheblast furnace process 1 1. Iron is made by reacting iron ore iron oxide and impurities, coke a reductant and limestone caco 3 in a blast furnace. 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. Modern blast furnaces produce more than 10,000 tonnes per day. Blast furnace ironmaking a view on future developments. Others include pellets, sinter, lump ore, limestone and so on. Most blast furnace iron is the raw material for oxygen steelmaking, where the molten iron is refined to produce the worlds most popular metal for engineering applicationsrolled steel. Fuel is also used at double the rate of regular furnaces, so the number of items smelted per fuel stays the same. The incorporation of blast furnace flux in the sinter saves fuel in the blast furnace. Valia, scientist, ispat inland inc introduction a world class blast furnace operation demands the highest quality of raw materials, operation, and operators. 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.
Eafs range in capacity from a few tons to as many as 400 tons, and a steelmaking shop can have from one to five furnaces. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. The book focuses on the control of the blast furnace process with respect to thermal control, gas flow control and casthouse operation. Materials balance calculation procedure in coke making. Kinetics and modeling of iron making blast furnace overview the iron making blast furnace is a complex multiphase flow reactor. Creating steel from lowgrade iron ore requires a long process of mining, crushing. Charging of carbon iron composite cic in blast fur nace. The raw ore is removed from the earth and sized into pieces that range from 0. Extraction of iron metallurgy blast furnace and reactions. Introduction kobe steel started operation as an integrated steel manufacturing company with the blowingin of the no. 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.
Energy flow and process gas utilisation in integrated steelworks. New developments in iron making process iron units in various forms are required for making steel. Smelting method used in the extraction of iron definition smelting is the process in which ore is mixed with purifying or heat generating substance like limestone and coke, they are heated at high temperature in an enclosed furnace. List ofsymbolsandabbreviations xi chapteri introduction oftheblast furnace process 1 1. The iron found in iron ores are found in the form of iron oxides.
Sulphur has to be removed first in a separate process. A realtime 3d measurement system for the blast furnace burden. Blast furnaces are used to produce pig iron from iron ore for subsequent. The burden charge consisting of iron oxide, flux and coke and it provides through the throat from the top of the furnace. In a blast furnace, fuel coke, ores, and flux limestone are continuously. Iron and steel industries consumes enormous amount of energy and contributes significantly in carbon dioxide emission. Iron fe is a relatively dense metal with a silvery white appearance and distinctive. Junichiro yagi, research institute of mineral dressing and metallurgy. 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. The extraction of iron from its ore is a long and subdued process, that helps in separating the useful components from the waste materials such as slag. Modern blast furnace ironmaking an introduction pdf.
Iron making mm15020 5th sem b tech department of metallurgy and materials engineering v. Silicon and aluminum often occur in iron ores as quartz, aluminum silicate clay minerals, or gibbsite. Iron making in mini blast furnace mbf the blast furnace ironmaking process had, until recently, been the unchallenged method of making hot metal on a large scale. This concentrated ore is mixed with limestone caco 3 and coke and fed into the blast furnace from the top.
Once a blast furnace is started it will continuously run for four to ten years with only short stops to perform planned maintenance. How a blast furnace works introduction the purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. 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. Blast furnaces have played a major part in pig iron production because of their high heat and gas utilization efficiency, mass production. Iron ore is usually a mixture of iron and vast quantities of impurities such as sand and clay referred to as gangue. Increased use of natural gas in blast furnace ironmaking. As a starting point, the blast furnace is seen as a simple iron ore smelter, while gradually the physical. How pig iron is converted into iron and steel in blast. 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. Iron oxides can come to the blast furnace plant in the form of raw ore, pellets or sinter. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. It is in the blast furnace that extraction of iron occurs. A good burden surface shape can improve gas flow distribution.
This guideline of safety is applicable to blast furnace dept. Scribd is the worlds largest social reading and publishing site. Process monitoring of iron making process in a blast furnace with pcabased methods bo zhoua, hao yea,n, haifeng zhangb, mingliang lib a department of automation, tsinghua university, beijing. Smelting reduction iron, manufactured without a blast furnace and without coke. With modern blast furnace ironmaking an introduction the reader has a compact compendium of the blast furnace process available.
Magnesium powder is blown through the molten iron and the sulphur reacts with it to form magnesium sulphide. All students, freshers can attemp or download metallurgical engineering physical metallurgy quiz questions with answers as pdf. Principle of iron making by blast furnace by a k biswas download free ebooks online. Iron ore, limestone and coke is the stock of the blast furnace. Pdf evolution of blast furnace process toward reductant. 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. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. Pdf blast furnace has been regarded as a highly optimized process as a result of. In the smelting reduction process, pelletized iron oxide ore or fine ore powders are prereduced in a fluidized bed or reduction shaft. Pdf within many industries there is a constant drive to reduce environmental. Decarbonisation options for the dutch steel industry pbl.
Analysis, control, and optimization uses a fundamental first principles approach to prepare a. Draw the diagram of a blast furnace used in the extraction of iron and label the. Iron ore processing for the blast furnace creating steel from lowgrade iron ore requires a long process. It is suitable for students of metallurgy as well as for blast furnace operators and management. The cokemaking process involves carbonization of coal to high temperatures 1100c in. 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. This shows the advantage of production of pig steel rather than pig iron in. The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. Burden distribution equipment including the hydraulic distributor, a newand bettertop for blast furnace efficiency. 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. 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.
The blast furnace is a membersonly minigame situated in keldagrim for smelting bars. Process flow diagram of a dry slag granulation system with heat recovery system for fuel preheating. Shows how iron ore, limestone, and coke are handled and prepared for the blast furnace in the making of iron. Iron making process producing iron from iron ore methods in iron making process 1. 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. Till 1990, the blast furnace route of ironmaking had about 97% 527mt share of global iron production. The iron ore concentrate is now mixed and ready for the pelletizing process. The downward flow of the ore along with the flux in contact with an upflow of. Ironmaking plant is an integral part of any steelworks which. So this coke could be a source of the internal structure of blast furnace burden, and from the coal it contains certain amount of impurities like sulfur and some volatile melt like alkalis. The phoenicians, celts and romans helped in spreading iron making technology. The unique characteristics of the finex process and its ability to use lowcost raw materials mean that both capital investment and production costs are much lower than in the blast furnace route. Thus far, diagnosis of abnormalities in furnaces still mainly relies on the personal experiences of individual workers in many iron works.
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