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. A blast furnace is a special type of furnace for smelting iron from ore. The forging furnace is used for preheating billets and ingots to attain a forge temperature. The blast furnace bf is the most widely used ironmaking. Process analysis for blast furnaces by the discrete element method. 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. 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. Sintering or pelletising improves the blast furnace operation and reduces energy consumption. The advantage of the induction furnace is a clean, energyefficient and wellcontrollable melting process.
The purpose of a blast furnace is to reduce and convert iron oxides into liquid iron called hot metal. Annular space it is the difference between the stock line radius and the large bell radius. Blast furnace an introduction blast furnace is the focus of any integrated steel plant. For the past few days, a small number of users has been consistently crashing the two major blast furnace ccs donationbf and truebf, as well as world 358 by taking over the pump and overheating the furnace. Us3216819a us37640a us3764060a us3216819a us 3216819 a us3216819 a us 3216819a us 37640 a us37640 a us 37640a us 3764060 a us3764060 a us 3764060a us 3216819 a us3216819 a us 3216819a authority us united states prior art keywords valve body gas tappet gases prior art date 19600621 legal status the legal status is an assumption and is not a legal conclusion. The furnace body in a rotary furnace is generally made from steel plate and welded to form the barrel, which can be up to 230 m in length. Blast refers to the combustion air being forced or supplied above atmospheric pressure.
Coke production for blast furnace ironmaking by hardarshan s. Oct 11, 20 glossary of terms used for a blast furnace. Introduction blast furnace is the mostly applied facility for the pig. Chemistry elements lying at top of reactivity series are more reactive than elements lying below them in series. Calculation of blast furnace size is empirical in nature. Pdf using blended learning method, blast furnace subject was.
Fuel is also used at double the rate of regular furnaces. Whitfield, peter, design and operation of a gimbal top charging system pdf, archived from the original pdf. Blast furnaces are used to produce pig iron from iron ore for subsequent. Owater channel isolated stave gets hotter oeventually furnace shell gets hot and cracks occur nonfixed connection stave moves. And a piece of good news at the end of the article we have two surprises, one is i give you the pdf of this article and the second is a quiz on cupola furnace for practice. The principle of blast furnace operational technology and. When a larger amount of coke exists, relatively, at the center of a blast furnace, the high temperature gas, consisting mainly of co generated at the tuyeres. Valia, scientist, ispat inland inc introduction a world class blast furnace operation demands the highest quality of raw materials, operation, and operators. The blast furnace at saugus features a fieldstone chimney stack that stands 21ft. The blast furnace at saugus iron works national historic site. The working of electric furnace includes charging the electrode, meltdown period melting the metal and refining. Extraction of iron metallurgy blast furnace and reactions. Blastfurnace gas, for example, which occurs as a byproduct inside the blast furnace and is used as a fuel gas for heating up the blastheating systems to generate hot air, contains twenty to twentyfive percent carbon monoxide. Blast furnace bleeder valve operation download pdf info publication number us3216819a.
A blast furnace is usually built with a steel case and bricks made of. Jan 06, 2018 cupola furnace is a melting device used to melt cast iron, niresist iron, and some bronzes and it is used in foundries. A wind box cast iron encircles to the outside of the furnace bottom. The shape of the cupola is cylindrical and the equipment is arranged in the vertical fitted with doors.
Creating steel from lowgrade iron ore requires a long process of mining, crushing. Glossary of terms used for a blast furnace ispatguru. Two large blast furnaces that began their operation in 2009 and 2011 respectively. Optimizing blast furnace operation to increase efficiency and. Optimizing blast furnace operation to increase efficiency.
Blast furnaces bfs are a critical part of the manufacturing procedure for the largescale integrated iron and steel industry and have working principles totally. The length of the furnace body can vary dramatically depending on the application, however, it becomes harder to maintain a uniform temperature throughout the chamber the longer the furnace. 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. The refractory materials applied in the furnace hearth. 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 blast furnace 1 the blast furnace by chan, sam and elly 2 what is a blast furnace. The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. The inside of the original furnaces were lined with firebrick which was imported from england. Alumina content of refractories varies depending on in which zone of the blast furnace they are used for lining. Production of pig iron in a blast furnace 9 scheme of a blast furnace content. Jul 12, 2019 blast furnace and process description. In a blast furnace, fuel coke, ores, and flux limestone are continuously supplied through. Coke is the most important raw material fed into the blast. The charge, which consists of iron ore, coke and limestone etc. It was the smelting unit where raw materials were transformed into molten iron. A packed bed in a blast furnace is sup ported by the formation. They can be up to 60 metres 200 ft tall and 15 metres 49 ft in diameter. The period of the blast furnace operation is limited by the life of the furnace hearth life. A wooden charging bridge extends from a bluff to a charging hole at the top of the chimney stack.
Working toward technology demonstration the ulcosbf developments in europe ir. The heavy and light scrap in the large basket is preheated with the help of exhaust gas. 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. Blast furnace and process description chemical engineering. Induction furnace capacities range from less than one kilogram to one hundred tonnes, and are used to melt iron and steel, copper, aluminium, and precious metals. The important zones that smelt iron ore are described starting from the blast furnace hearth and working upward. Air which supplies the oxygen necessary to burn the fuels forced through the cupola by a blower. Blast furnace is currently unusable as a result of widespread crashing for the past few days, a small number of users has been consistently crashing the two major blast furnace ccs donationbf and truebf, as well as world 358 by taking over the pump and overheating the furnace. Nov 27, 2011 the optimal working height of blast furnaces in smelting titanomagnetite sinter and pellets is 10. Modeling of burden distribution in the blast furnace doria.
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 agglomeration and pelletization of iron ores requirements to individual components of a blast furnace charge time for the study. Mini blast furnaces mbfs are ideally suited to small scale operations. In such cases dual fuel fired boiler is more effective from economic and environment point of view. Blast furnace gas, for example, which occurs as a byproduct inside the blast furnace and is used as a fuel gas for heating up the blast heating systems to generate hot air, contains twenty to twentyfive percent carbon monoxide. The burden charge consisting of iron oxide, flux and coke and it provides through the throat from the top of the furnace. Forging furnaces use an open fireplace system and most of the heat is transmitted by radiation.
A blast furnace charge consists of ore, fluxes and fuel. What is the working principle of an electric arc furnace. Agglomeration techniques with sintering and pelletising in details. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. Forthis purpose the mathematical model of a blast furnace has been used szargut, 1983. Blast furnace is a counter current heat and mass exchanger in which reduction and smelting of metallic mineral takes place. Stoves are also provided with waste heat recovery system and coke oven gas enrichment facilities, if coke oven gas is available. Blast furnace operation an overview sciencedirect topics.
Development of mathematical model of blast furnace1115kb. All the three ingredients are crushed into small round pieces and mixed and put on a hopper which controls the input. These improvements to the processing of scrap steel comprised of larger more efficient and higher capacity furnaces. The analysis shows the preference of students to work with different. 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. Blast furnaces are similar to furnaces, but can smelt only ore blocks and toolsarmor made of iron, gold or chainmail. The coke layer has a gasflow resistance smaller by a factor of 10 compared to that of the ore layer and has a high gaspermeability. Working height of the furnace it is the vertical distance between the centerline of the tuyeres and the stockline. 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. Converter gas, which is produced whenever carbon is extracted from pig iron in the converter plant by. Certificate this is to certify industrial training work entitled detail study of working in blast furnace area vizag steel plant that is submitted by arijit karmakar 12mme29, student of 2 nd year,b. 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. The cupola can be made of any size and the size of the cupola is measured in diameters which range from 1. 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.
Stateoftheart computational fluid dynamics model optimizes fuel rate in. For those that arent familiar with the mechanics of the blast. Tech, metallurgy and materials engineering of national institute of technology, durgapur, during the academic year 202014 and it has found worthy of acceptance. A cross section of a blast furnace showing nomenclature of different portion is shown in fig 1. Principle,construction, working, advantages, disadvantages and application january 6. Since mbfs are small working volume ranges between 100 370 m3. The furnace temperature is maintained at around 1200 to 1250 oc. Blast furnace is currently unusable as a result of. For larger furnace height, relatively immobile refractory batch is formed in the bosh and periodically slips to the hearth, with impairment of the furnaces thermal state. We work closely with subcontractors and construction companies to minimise the impact of major work on ongoing operations, the outofoperation or. These models have been used for the analysis and the opera tion design of actual operation. The optimal working height of blast furnaces in smelting titanomagnetite sinter and pellets is 10.
The typical load is 5 to 6 ton with the furnace operating for 16 to 18 hours daily. Alumina refractories these refractories are used for lining of blast furnace. Reverberatory furnace, in copper, tin, and nickel production, a furnace used for smelting or refining in which the fuel is not in direct contact with the ore but heats it by a flame blown over it from another chamber. 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. When i am working in pearson, i worked on this project 2. The ore part of a charge consists of iron ores and concentrates, manganese ores and various types of scrap containing iron. This box is connected to the furnace blower pipe known as the blast pipe. 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.
Blast furnace is currently unusable as a result of widespread. The cleaned blast furnace gases are used to preheat stoves and boilers within the steel plant. Blast furnaces used in the isp have a more intense operation than standard lead. A major advance in bf ironmaking has been the use of pulverized coal which partially replaces. The second world war saw a steep increase in the use of these furnaces leading to the modern electric arc furnace design operation and working principles. Blast furnace is used to reduce the iron ore to iron. The furnaces were of the steam, hot blast coke type, constructed entirely of stone and rectangular in shape. The identification of the influence of the working parameters of the blast furnace upon the net calorificvalue of bfgas is of great practical importance from the point of view of energy management of ironworks. By 1850 as the furnace size increased, the furnace top could be. The working principle of water tube boiler is very interesting and simple. A mini blast furnace mbf, which can be viewed as is a miniature version of conventional large blast furnace, also has a few additional characteristic features known for their simplicity and economy. Aug 04, 2011 the purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals. By 1850 as the furnace size increased, the furnace top could be closed.
Blast furnace products and there use size of blast furnace design of blast furnace is evolved through experience. The sintering or pelletising process prior to the blast furnace operation is added to allow blending of iron ores and also to control the size of the blast furnace feed. In a blast furnace, iron ore reacts with hot coke to produce pig iron. The furnaces were of the steam, hotblast coke type, constructed entirely of stone and rectangular in shape. Comparative performance evaluation of blast furnace. In steelmaking, this process, now largely obsolete, is called the openhearth. A blast furnace also represents a huge overhead cost because, once fired up, it typically runs for six to 10 years, giving an operator little flexibility. Blast furnace extraction of iron from blast furnace class 12 ncert chemistry blast furnace working animation extraction of iron metallurgy of iron.
Electric arc furnace design operation and working principle. The blast furnace is a huge, steel stack lined with refractory brick. So today we discuss the working principle of cupola furnace as well as see the construction, advantages, disadvantages, and applications of cupola furnace. Oct 04, 2016 blast furnace extraction of iron from blast furnace class 12 ncert chemistry blast furnace working animation extraction of iron metallurgy of iron. As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. The blast furnace is a countercurrent reactor where rising hot gases heat and chemically reduce iron oxides in the descending charge materials.
This doctoral dissertation is the result of my research work carried out at the thermal and flow. The advantage of the induction furnace is a clean, energyefficient and wellcontrollable melting process compared to most other means of metal melting. A brief summary of the history and archaeology of this early 18th century charcoal blast furnace, planned in 17 by abraham darby of coalbrookdale and managed between 1714 and 1736 by john kelsall, the wellknown quaker. Kobe steel started operation as an integrated steel manufacturing company with the blowingin of the no. Jan van derstel ieaghgiets iron and steel industry ccus and process integration workshop tokyo, japan 4 7 november 20.
Air heated in the blast furnace stoves, is applied from the bottom of the. And a piece of good news at the end of the article we have two surprises, one is i give you the pdf of this article and the second is a. Now there are nearly 700 blast furnace available in world. Hot blast stoves supply hot blast after heating cold air provided by turbo blowersfans to blast furnace through hot blast main, bustle main, tuyere stocks and tuyeres. Pdf technological changes in blast furnace iron making. In earlier days, blast furnace bf top used to be open with the gas from the furnace escaping into the atmosphere and burning, causing environmental issues while wasting considerable energy. Pdf as a promising method to strengthen the blast furnace smelting and to realize reduced fuel operation, highproportion pellet charging has. Jan 08, 2017 when i am working in pearson, i worked on this project 2. Ppt the blast furnace powerpoint presentation free to. The iron ore concentrate is now mixed and ready for the pelletizing process. Temperature at lean blast furnace top gas operation. Blast furnace is currently unusable as a result of widespread crashing.
Pdf technological changes in blast furnace iron making in. 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. Pdf blast furnace performance under varying pellet proportion. Stoves absorb heat from the combustion of blast furnace gases with air and transfer this heat to the air blast that will be injected into the blast furnace tuyeres.
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