This book focuses on the control of the blast furnace process with respect to thermal control, gas flow control and casthouse operation. This concentrated ore is mixed with limestone caco 3 and coke and fed into the blast furnace from the top. A blast furnace, after it is blown in and the production of hot metal starts, runs for a large number of years before it is put down for relining. Competition in industry drives higher production rates. New developments in iron making process iron units in various forms are required for making steel. 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. Recently, the usage of nut coke in the modern blast furnace is accompanied by higher production and lower reducing agent rates. Modern blast furnace bf and converter bof gas cleaning a report of stateoftheart technology by franz reufer and christian davidi synopsis. Alternative methods known as direct reduction are used in over a score of countries, but less than 5 percent of iron is made this way. In the second edition of modern blast furnace ironmaking, we have included our insights. The ironmaking blast furnace bf is an efficient chemical reactor for producing liquid iron from solid iron ore, where the solids of coke and iron ore are charged in alternative layers and different chemical reactions occur in the two solid layers as they descend. In modern practice, the combined iron plus coke burden is self fluxing and virtually no limestone is required at the. In modern blast furnaces due to high injection rate and low coke rate.
Such respective reacting burden layers have not been considered explicitly in the previous bf models. Optimisation of the blast furnace burden based on its primary slag. The metallic iron produced by such a furnace contains a relatively high proportion of. Extraction of iron metallurgy blast furnace and reactions.
Modern blast furnace can reach a fuel efficiency of about 50%, according to the top gas composition, is illustrated in figure 1. Mar 20, 2017 shows how iron ore, limestone, and coke are handled and prepared for the blast furnace in the making of iron. An obsolete technology for making steel by carburization of iron. Modern blast furnaces produce more than 10,000 tonnes per. After awhile a guy like me get tired of just melting aluminum. Hot blast stove, apparatus for preheating air blown into a blast furnace, an important step in raising the efficiency of iron processing. During the 1860s, iron producers from the cleveland dist. It is suitable for students of metallurgy as well as for blast furnace operators and management. This book describes the blast furnace process for operators.
The world leader in ironmaking solutions primetals technologies. 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. Silicon and aluminum often occur in iron ores as quartz, aluminum silicate clay minerals, or gibbsite. The production and development of the ironmaking process in china are. With modern blast furnace ironmaking an introduction the reader has a compact compendium of the blast furnace. May 05, 2015 methods of shutting down a blast furnace. And even bronze can fail to fulfil an inner melting need. Your challenge the conventional blast furnace route is too costly and energyintensive to keep pace with dynamic market changes, where even short and. Then came the change from cold blast, charcoal furnaces to hot blast, coke furnaces in the mid1800s which brought iron making into the modern era. The temperature regime in the blast furnace shaft is such that it can be assumed a zone of mixedcontrol exists. Large blast furnace, china, production, ironmaking, future development. Iron making in the furnace usually continues for about ten years before the furnace linings have to be renewed.
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. Blast furnace equipment is in continuous evolution and modern, giant furnaces produce,000 tons per day. Modern cupola furnaces with hot blast produce about 100 thour i. Download 87 modern blast furnace stock photos for free or amazingly low rates. 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. Modelling of blast furnace with respective chemical. Recent trends in ironmaking blast furnace technology to. Pdf technological changes in blast furnace iron making in. Blast furnace,blast furnace process,blast furnace application. Please practice handwashing and social distancing, and check out our resources for adapting to these times. Modern furnaces will take a charge of iron of up to 350 tons and convert it into steel in less than 40 minutes compared to 1012 hours in an open hearth furnace. The primary objective of iron making is to release iron from chemical combination with oxygen, and, since the blast furnace is much the most efficient process, it receives the most attention here. The blast furnaces are the starting p01nt of the entire process. The iron ore concentrate is now mixed and ready for the pelletizing process.
Modern blast furnace ironmaking an introduction pdf. As a starting point, the blast furnace is seen as a simple iron ore melter, while gradually the physical, chemical and metallurgical background is clarified. Analysis, control, and optimization uses a fundamental first principles approach to prepare a blast furnace mass and energy balance in excel. In conclusion, modern techniques should be applied to the ironmaking process to. The production of large blast furnaces during 2016 and future. The principle of blast furnace operational technology and. 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. The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. Download modern blast furnace ironmaking an introduction. The blast furnace is a hightemperature, pressurized countercurrent reactor with dynamic process conditions. The major repair in a blast furnaces campaign life is the replacement of the lining. 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.
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 furnace is heated constantly and is recharged with raw materials from the top while it is being tapped from the bottom. It is suitable for students of metallurgy as well as for blast furnace. The properties of the original raw ore are changed in this process. If you like this video then please share this with your friends. This continuous run of the blast furnace is known as campaign life. Robust descriptions of the main equipment and systems, process technologies, and best practices used in a modern blast furnace plant are detailed. 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. Two large blast furnaces that began their operation in 2009 and 2011 respectively.
Cuttingedge technologies for ironmaking to meet your individual requirements primetals technologies is the only global provider of technological solutions along the entire valueadded chain of iron making and the largest provider of metallurgical automation solutions worldwide. Blacksmith blast furnace abandoned blast furnace epic view of blast furnace smoke dust metal fire technology glowing steel tube during production in a modern rolling mill in the industry old brick building with blast furnace from an old closed down steel mill or ironworks. With the rapid development of ironmaking industry in china, the iron. The initial sentiment of the time might have faded, but the blast operation continues. Blast furnace bf remains the dominant ironmaking process. Although the basic ingredients of an iron ore blast furnace has changed little over the last hundred years or so, the furnaces themselves have been modernized to improve efficiency and the purity of the iron and steel. In this work, a new method for optimisation of blast furnace burdens. The basic materials used for the manufacture of pig iron are iron ore, coke, and limestone.
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. Many of the innovative ironmaking technologies that have emerged in. Since almost 15 years paul wurth umwelttechnik gmbh in essengermany is dedicated to bf and bof gas cleaning. Model study of blast furnace operation with central coke charging. Blast furnaces are used to produce pig iron from iron ore for subsequent. Ios press ebooks modern blast furnace ironmaking an.
In the blast furnace route of ironmaking, metallurgical coke are used for four. John ricketts this book describes the blast furnace process for operators. So it was only a matter of time before i set out to melt iron. The equipment and systems of modern blast furnace technology are designed for the harsh environment. These materials are prepared at the ore preparation plant, sinter plant and. The authors have very extensive experience as operators as well as consultants to many steel plants worldwide. The blast furnace is the first step in producing steel from iron oxides. The charge for agglomerate production comprises three basic parts. Sudheer steel making value chain steel making flow line steel making flow line finishing history and evolurtion what is iron making. Pdf iron and steel making is one of the most intense energy.
While blast furnaces produced much larger amounts of iron, they required greater amounts of raw. The introduction and process optimization research of oxygen blast furnace ironmaking technology qingguo xue, zeshang dong, jingsong wang, zeyi jiang, haibin zuo, xuefeng she and guang wang abstract in order to reduce the energy consumption from iron and steel industry, decreasing coke rate by establishing oxygen blast furnace. The production of iron in a blast furnace is a continuous process. Modern blast furnace ironmaking an introductio 001 2 scribd. 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. Blast furnace operation at a glance the purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. Blast furnace products and there use size of blast furnace design of blast furnace is evolved through experience. 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. Effect of enriching the blast with oxygen on the production cost of pig. Now there are nearly 700 blast furnace available in world. Modern iron making handbook op mli handbook series r h tupkary v r tupkary on free shipping on qualifying offers this book comprehensively deals with all of the key topics of iron making including blast furnace plants.
Blast furnace economics are such that larger units have lower unit production costs, hence there has been a trend to bigger and bigger furnaces. Primetals technologies has provided blast furnace engineering, project excellence and expertise to customers worldwide for over a century. Efficient and environmentally friendly smelting reduction a vai ironmaking technology. Methods of shutting down a blast furnace ispatguru. Describes the principles of the blast furnace process and especially the control of the process. Blast furnace reline project and it is possible that it will not go ahead. The blast furnace remains an important part of modern iron production. The main purpose of sintering of iron ores agglomeration is to convert fine raw materials into lumpy material for pig iron making in the blast furnace. This project has been performed to increase the steel making production capacity of esfahan steel company in iran from 2. Blast furnaces are often subjected to extreme physical stress resulting in deterioration of the interior, thus requiring periodic repair.
Ironmaking 101 from ore to iron with blast furnaces. 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. Blast furnace hot metal and recycled steel in the form of scrap have been the main sources of iron. Presentation at edrc kolkata on 14th feb 2007 by n. Smallvolume blastfurnaces the future of blastfurnace. So i decided to build this small portable cupola furnace to do just that. Interaction reaction between the degradation of coke and the reduction of iron ore in oxygen blast furnace under hydrogenenriched operation. Many innovative operations have been adopted in modern ironmaking bfs for. Modern blast furnace stock photos download 87 royalty free. The equipment and systems of modern blast furnace technology are designed for the harsh. The 150 year history of the japanese steel industry dates from the first western blast furnace, which was built by t. Ramm,modern blastfurnace smelting in russian, metallurgiya.
Blast refers to the combustion air being forced or supplied above atmospheric pressure. This technology represented a significant step forward in the complexity of iron production. Unlike modern steel making, it increased the amount of carbon in the iron. Preheated air was first used by james beaumont neilson in 1828 in glasgow, but not until 1860 did the englishman edward alfred cowper invent the first successful hot blast stove. In modern day, blast furnace operation is done within a well organized setup. Derwentcote steel furnace, built in 1720, is the earliest surviving example of a furnace.
Modern blast furnaces produce more than 10,000 tonnes per day. T, burla person involved name designation and email. This book describes the principles of the blast furnace process and especially the control of the process. Blast furnace will be continued for another thousand years because iron can be smelted at an economical price. Review ironmaking technology for the last 100 years. 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. It was apparently developed before the 17th century. Blast furnace ironmaking is a multistep reduction of iron oxides at elevated temperatures. The modern blast furnace reconsidered continued from page i sense of american exceptionalism in furnace development and have neglected the influence of european models of furnace design and management. In modern blast furnaces a campaign life of 15 years to 20 years is expected. The world leader in ironmaking solutions primetals. By mathematically modeling the blastfurnace smelting of conversion pig iron with a. Amongst all the ironmaking processes, the blast furnace technology, which has been around the longest, still holds the dominant position.
Products ironmaking and steelmaking modern blast furnace. Mar 02, 20 the temperature regime in the blast furnace shaft is such that it can be assumed a zone of mixedcontrol exists. Till 1990, the blast furnace route of ironmaking had about 97% 527mt share of global iron production. In the ironmaking blast furnaces, nut coke 1040 mm. Ancient iron making blast furnace iron making raw materials blast furnace reaction. Milestones of our blast furnace operation technologies tamura categorized our history of pig iron making into the following three periods, in an article. With modern blast furnace ironmaking an introduction the reader has a compact compendium of the blast furnace process available. 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. The major raw materials utilised in iron making are iron ore and coke. As a starting point, the blast furnace is seen as a simple iron ore melter, while gradually the physical, chemical and metallurgical. The first blast furnaces appeared in the 14th century and produced one ton per day. 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.
An efficient recycling of inplant fines by its conversion into briquettes with proper mechanical strength is applied in some blast furnaces to exploit the iron and carbonrich residues. Iron making free download as powerpoint presentation. Modern blast furnace operation at integrated steel works in japan started in 1901 with the first blowin of higashida no. Calculation of blast furnace size is empirical in nature. The better understanding of iron making reactions and improved equipment evolved into the harddriving furnace operation centered in.
In some countries like sweden, electric blast furnaces are used because of the unavailability of charcoal and coke. Blast furnace ironmaking an overview sciencedirect topics. For general information about merchant pig iron, please visit the pig iron page. Composition of a charge in the production of pig iron in a blast furnace.
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. Iron ore smelting process using modern blast furnaces. 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. In the blast furnace, the reducing gas ispredominantly co with varying amounts ofhydrogen depending upon the moisture content ofthe blast and other blast additives like fuel oil ornatural gas. Shows how iron ore, limestone, and coke are handled and prepared for the blast furnace in the making of iron. 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.
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. Creating steel from lowgrade iron ore requires a long process of mining, crushing. It is in the blast furnace that extraction of iron occurs. In this video, you will learn all about blast furnace and its uses.
856 136 1493 704 432 232 244 1161 430 604 778 593 1492 1252 252 1408 1024 242 184 1286 1385 697 1044 527 1021 457 327 1192 1274 1179