The blast furnace operates as a countercurrent exchange process whereas a bloomery does. Blast furnace products and there use size of blast furnace design of blast furnace is evolved through experience. 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 countercurrent gassolids reactor in which the descending column of burden materials coke, iron ore and fluxes.
Automation and control in iron and steel industries. Direct reduced ironis a process in which iron ore is reduced to the solid state or by gaseous reducing agent. They can be up to 60 metres 200 ft tall and 15 metres 49 ft in diameter. In general it has around 95 percent fe content, plus certain impurities such as carbon say, 4 percent, and silicon, manganese, phosphorous and sulfur. Larger blast furnace, use of better prepared burden, recovery of waste energy, and maximum recovery of slag characterize the iron making technology proposed for vsp. Compared to this, elsewhere furnaces up to 5070 m 3 had.
It is heated and the iron oxides are partially reduced. A64414 standard terminology relating to iron castings free download as pdf file. 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 economics are such that larger units have lower unit production costs, hence there has been a trend to bigger and bigger furnaces.
Desulfurization of pig iron outside the blast furnace. Pig iron is produced by smelting or iron ore in blast furnaces or by smelting ilmenite in electric furnaces. In a blast furnace, iron ore reacts with hot coke to produce pig iron. By malik mubashir university of the punjab lahore, pakistan 2. Cupola furnace is the cheapest means for converting pig iron or scrap metal into gray cast iron. Clevelandcliffs plans to price hbi with pig iron as. 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 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. Iron blast furnaces prod uce molten iron pig iron that can b e cast molded into products.
Now there are nearly 700 blast furnace available in world. This is how iron ore is turned into steel business insider. Sometimes, it is also used for melting nonferrous metals and alloys. The product of the small, local furnaces in china may well contain organic matter as well, 1. The basic oxygen furnace converts the pig iron to steel by oxidation of excess carbon and other elements. Calculation of blast furnace size is empirical in nature. Pig iron is the product of smelting iron ore also ilmenite with a highcarbon fuel and reductant such as coke, usually with limestone as a flux. 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.
Pig iron is the intermediate product of smelting iron ore. Mini blast furnace mbf is the most proven technology, as revealed by one recent global iron production data. Extracting iron from iron ore using a blast furnace. A blast furnace is usually built with a steel case and bricks made of. A computer has been used to find the relationship between blast furnace smelting indices and the sulfur and silicon content of the pig iron, on the basis of mean. Blast furnace is the mostly applied facility for the pig iron production. Step 2a the blast furnace the sinter is added through a hopper at the top of the blast furnace. China iron blast furnace, china iron blast furnace suppliers and manufacturers directory source a large selection of iron blast furnace products at blast furnace,granulated blast furnace slag, iron melting furnace from china. For annual book of astmstandards volume information, refer to the standards document summary page onthe astm website. Process monitoring of ironmaking process in a blast furnace. Using coal coke immersive engineering for fuel, it converts iron ingots and blocks into steel. 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. Blasts furnaces are used for smelting during the production of metals such as iron, lead, zinc, and copper.
This book discusses the importance of blast furnace process as a complete operation. To ensure that the production process maintains a high and stable level of quality, these materials have to be metered precisely and supplied to the blast furnace in batches. Development of pig iron and molten slag level measurement. The principal function of a blast furnace is to continuously produce liquid hot metal viz. Mar 06, 2016 introduction and construction blast furnace. Production of pig iron in a blast furnace 5 these properties and is brittle both when cold and after heating.
In 1870 furnace superintendent john downing had over 25,000 bushels of charcoal on hand. The study in reference 7 shows that slag has good flowability in case that slag basicity is 0. Cast iron is made by melting pig iron with coke in a cupola furnace to remove sulfur. A typical blast furnace along with its various parts is shown in fig. Blast furnaces were utilized for smelting and refining industrial metals, generally iron, and were widely used in the creation of steel in the pittsburghwestern pennsylvania region during the united states 20th century industrial boom. Kobe steel manufactures foundry pig iron at its kakogawa works and kobe works using blast. The principle of blast furnace operational technology and. Paper presents the results from the study of the effect of materials. Iron ore, limestone and coke is the stock of the blast furnace. Kalinga iron works is successfully operating three small blast furnaces with volumes less than 100m3 each, an mbf of 175m 3 capacities was commissioned in goa in 1992 and nine more mini blast furnaces with installed capacity of 0. Raw materials in blast furnace are iron ore, metallurgical coke and suitable fluxes like dolomite, lime etc.
Blast furnace simple english wikipedia, the free encyclopedia. Listed below are the highlights of the blast furnace at vsl steels. The raw materials require 6 to 8 hours to descend to the bottom of the furnace where they become the final product of liquid slag and liquid iron. 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. 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. All the three ingredients are crushed into small round pieces and mixed and put on a hopper which controls the input. The smelting process in cupola furnace is also consid ered to be competitive. The blast furnace is a huge, steel stack lined with refractory brick. A mixture of iron ore and coal is then heated in a blast furnace to produce molten iron, or pig iron, from which steel is made. Improved blast furnace official feed the beast wiki. Blast furnace gas is produced during the iron oxide reduction in blast furnace iron making in which iron ore, coke and limestone are heated and melted in a blast furnace and is an indigenous process gas of the steelworks industry pugh et al.
Coal is cleaned of impurities in a coke furnace, yielding an almost pure form of carbon. 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. Find, read and cite all the research you need on researchgate. Ironmaking blast furnaces consist of several zones.
The formation of iron and steel the blast furnace 2. Based on the comparison of the blast fur nace technology with other alternative production. The cupola is a most widely used foundry furnace for melting ferrous metals and alloys. State of direct reduction and reduction smelting processes j. Direct reduction processes direct reduction is defined as a process of producing solid iron product. Pig iron composition for optimum blast furnace and converter. Use of granulated pig iron gpi in the electric arc. The restoration of an iron making blast furnace automation system is a stimul ating challenge that involves process, electrical and automation competences and that. The blast furnace has been the dominant technology for iron production for centuries. The most common ore of iron is called haematite iron iii oxide.
Us steelmaker nucor and austrias voestalpine developed north american hbi and dri plants to supply us and mexican mills. The melt iron and slag and the remaining coke collect in the lower part of the blast furnace. Coke is cheap and provides both the reducing agent for the reaction and also the heat source. This is because the electric furnace can be operated with the proper metallurgical conditions for the production of pig steel rather than pig iron, and because in a possible design of shaft furnace similar to the blast furnace there is a greater chance for the production of a larger tonnage than is possible in the case of furnaces used in. Milestones of our blast furnace operation technologies. Publication date 1908 topics cast iron, blast furnaces publisher. Pdf technological changes in blast furnace iron making in. Pig iron and refined iron ore pellets briquetted iron can also be. For the 180m3 npi bf that i have seen, the slag basicity is controlled to be more than 0. Theory and practice paperback january 1, 1979 by j. Pig iron is produced in blast furnace by reducing iron ore with carbon monoxide indirect reduction and carbon direct reduction. Blast furnace operation an overview sciencedirect topics.
How pig iron is converted into iron and steel in blast. Total worlds dri output in 1998, 1999, 2000 and 2001 in % 2 figure 2. Pdf the production of large blast furnaces of china in. The period of the blast furnace operation is limited by the life of the furnace hearth life. From the late twentieth century, the production of lowsi pig.
Air pollution problems of the steel industry technical. Extraction of iron in a blast furnace the significant reactions occuring within the blast furnace can be described via the following steps showing how the reducing agent varies depending on the height in the furnace i. Im new to the blast furnace and would love some advice from you guys. Finegrained iron ore is processed into coarsegrained clumps for use in the blast furnace. This book includes a set of equations that accurately describe stoichiometric and enthalpy balances for the process and which are consistent with observed. Up to today, lining materials have been supplied to about 50 blast furnaces in italy and abroad always achieving excellent results and acquiring a solid reputation among the users. Slagging system of conventional bf cannot be used for npi bf. 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. What is the method of production of pig iron by using a. The amount of ore to be used per unit of pig iron made is. It can be poured directly into molds but product is brittle, and lacking in.
I, pig iron is made in a blast furnace by smelting iron ore with coke and limestone. Their physical plants were bigger than forges and the expense to erect one was considerable. Kobe steels pig iron comes in convenient shapes that require no division for use. Introduction blast furnace is the mostly applied facility for the pig. Pig iron blast furnace route international iron metallics association. The combustion of iron ore with other materials in the blast furnace produces molten pig iron, which is then converted to steel. In the combustion heat accumulation phase, heat energy in hot exhaust gas from a burner is accumulated in checker bricks and, in the ventilation phase, a large quantity of air is blown through the checker bricks to raise the temperature of the air. China iron blast furnace, china iron blast furnace. The blast furnace reduces practically all of the iron present in the ore into the pig iron, and, therefore, if the ore contains 50 per cent of metallic iron and the pig iron 90 per cent, it will take 0. Theory and practice presents theoretical, experimental, and operational evidence about the iron blast furnace as well as a mathematical description of its operation. 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 purpose of a blast furnace is to reduce and convert iron oxides into liquid iron called hot metal. 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. Other processes for extracting iron from its oxides are described in chapter 11.
Coke is produced by heating coal in the absence of air. 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. Pig iron has a very high carbon content, typically 3. The raw materials with which kobe steel charges its blast. With its diverse and sophisticated casting technology, foundry pig iron of better quality and higher reliability is in demand. Automation and control in iron and steel industries jurgen heidepriem university of wuppertal, germany keywords. Total worlds dri output by processes in 2001 in % 2 3. The process of preparing pig iron was using hot blast cupola hbc furnace.
Pdf the production of pig iron from crushing plant waste using hot. 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. Blast furnace ironmaking process using prereduced iron ore. The improved blast furnace is a multiblock machine added by immersive engineering. Live simple, live free tinyhouse prepper recommended for you. Sintering, blast furnace, oxygen blowing process, secondary metallurgy, continuous casting, electric arc furnace, hot rolling, cold rolling, processing lines. The term pig iron is generally applied to the metallic product of the blast furnace. In ironmaking, the blastfurnace process used to produce pig iron is designed to effectively remove oxygen from iron ore at temperatures as high as.
As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. The method used in blast furnaces have been used since the 1500s. Technology and developing trends of nickel pig iron blast. Two large blast furnaces that began their operation in 2009 and 2011 respectively. Modern blast furnaces produce more than 10,000 tonnes per. Smelting reduction technology is an alternative technology to the conventional blast furnace.
Smallvolume blastfurnaces the future of blastfurnace. Blast furnace gas has a high carbon monoxide co content and a low heating value, typical. This page looks at the use of the blast furnace in the extraction of iron from iron ore, and the conversion of the raw iron from the furnace into various kinds of steel. Tamura categorized our history of pigiron making into the. 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. Santanu chakraborty, in treatise on process metallurgy. 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. A blast furnace is a special type of furnace for smelting iron from ore. Sintering or pelletising improves the blast furnace. The materials put into a blast furnace may all be classed under four heads. Temperature of a blast furnace the physics factbook. Milestones of our blast furnace operation technologies tamura categorized our history of pig iron making into the following three periods, in an article. Pig iron production in poland relies almost exclu sively on ores imported from abroad.
The conventional method of measuring the pig iron and molten slag level is the emf electromotive force method,15 in which the voltage generated in a blast furnace is detected. A64414 standard terminology relating to iron castings. It may be possible to improve the productivity and flexibility of the blast furnace operation and also to substitute energy sources in the pig iron production. A hot blast stove is a facility to supply hot air to a blast furnace continuously. Slagging system specified in reference 8 is that slag basicity is 0. 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. Pig iron is an intermediate product of the iron industry, also known as crude iron, which is obtained by smelting iron ore in a blast furnace.
The common ores of iron are both iron oxides, and these can be reduced to iron by heating them with carbon in the form of coke. The refractory materials applied in the furnace hearth. Ironmaking 101 from ore to iron with blast furnaces. 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. When the temperature is high enough the iron oxides starts to soften and eventually melts. Extraction of iron in a blast furnace reduction haematite o. For general information about merchant pig iron, please visit the pig iron page. 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. 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. Charcoal and anthracite are also used as fuel and reductant.
The presentday methods of pig iron manufacture make possible the production of metal with a low sulfur content. Modern cupola furnaces with hot blast produce about 100 thour i. Extraction of iron metallurgy blast furnace and reactions. Such alloys of iron with a carbon content of about 4. While gasbased as well as coalbased dri production routes produced 2. The raw materials used include ore, sinter, coke, lime and various aggregates. Limestone is added to the blast furnace to capture impurities and. Unlike the crude blast furnace, the improved blast furnace will automatically export steel and slag immersive. Blast furnaces differ from bloomeries and reverberatory furnaces in that in a blast furnace, flue gas is in direct contact with the ore and iron, allowing carbon monoxide to diffuse into the ore and reduce the iron oxide to elemental iron mixed with carbon.
A variety of processes take place within the blast furnace, as the stock slowly moves downwards and temperatures increase. Blast furnace produces hot metal liquid iron using iron ore, coke, sinter, pellets and fluxes such as. Diy brick rocket stove cooking without electrical power duration. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. The fine particles of the stock, principally the fines fraction in the iron ore, tend to be entrained in the high velocity gas streaming between the interstices of the stock bed inside the furnace and are carried out of the furnace in suspension in the blast furnace top gases. The eastern european countries ship basicgrade and nodular pig iron produced from blast furnaces, with the us becoming a growing market. Modern blast furnaces produce more than 10,000 tonnes per day. It is the molten iron from the blast furnace, which is a large and cylindershaped furnace. The newlee iron furnace was constructed between 18 and 1835 by martin beaty in cumberland gap, tennessee. Furnaces also required a larger labor force to operate, and they had to be housed, fed and supplied with other goods and services. Our facility consists of a blast furnace that is of 262 m3 capacity and is used for producing pig iron. Please practice handwashing and social distancing, and check out our resources for adapting to these times. The largest blast furnace in india at that time was of 2000 m 3.
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