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 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. Therefore, the flow of alkali metals in and out of the reactor has to be controlled. The principle of blast furnace operational technology and. Click download or read online button to get blast furnace simulation book now. Many of the innovative ironmaking technologies that have emerged in. Calculation of blast furnace size is empirical in nature. This site is like a library, use search box in the widget to get ebook that you want. Efficient and environmentally friendly smelting reduction a vai ironmaking technology. Keeping in view for increasing quality of hot metal and its production rate. As a starting point, the blast furnace is seen as a simple iron ore melter, while gradually the physical, chemical and. Principles of blast furnace iron making theory and practice brisbane.
Noncoking coal can be used directly as a reducing agent and energy source up to 80% of the iron oxide fraction can be lump ore. 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 70 million net tons of steel recycled in 2000 were used to produce about 112 million net tons of new steel in the united states. The present paper deals with the salient features of the above said changes adopted for the improved productivity and efficiency of the furnace operation in the field of blast furnace iron making. In a blast furnace, fuel coke, ores, and flux limestone are continuously supplied through. 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. The blast furnace ironmaking system using prereduced ore twostage reduction system is a twostage ore reduction system that consists of a process for prereducing iron ore by using natural gas or some other suitable energy containing a comparatively small amount of carbon and a blast furnace process for further reducing. Feb 29, 2008 chatterjee has authored several books.
Us5395441a revert briquettes for iron making blast. In 2016, over 1 billion tonnes of molten iron were produced from 700 to 900 blast furnaces operating on every continent, except antarctica. The role of the blast furnace in steel production is discussed followed by the trends in blast furnace performance. A typical blast furnace along with its various parts is shown in fig. Iron is produced in blast furnaces by the reduction of iron bearing materials with a hot gas. Mar 20, 2017 shows how iron ore, limestone, and coke are handled and prepared for the blast furnace in the making of iron. Development of mathematical model of blast furnace1115kb. Main differences from the blast furnace route the main differences between corex and a conventional blast furnace route are. The success rate of alternative processes has been low, i. Blast furnace gas has a high carbon monoxide co content and a low heating value.
This concentrated ore is mixed with limestone caco 3 and coke and fed into the blast furnace from the top. The book focuses on the control of the blast furnace process with respect to thermal control, gas flow control and casthouse operation. Developments in alternative ironmaking springerlink. Specific coke or fuel consumption equivalent coke rate. Since the 1950s, significant research and development effort has been done in europe to make the blast furnace ironmaking technology and operation more efficient. Cost effectiveness analysis of hyl and drex dri te chnologies for the iron and steelking industry pa ge 7 steel making process and co 2222 emissionsemissionsemissions steel is primarily made by one of two processes. Consequently replacing the blast furnace is a formidable task. As for the mathematics model of a blast furnace of nippon steel corp. The metallic iron produced by such a furnace contains a relatively high proportion of carbon 4% and is passed to the steelmaking process as a liquid at approximately 1450c, called hot metal. The primary problem the blast furnace ironmaking approach is that many of these blast furnaces are relatively small, as compared to the. Included in this article also is a discussion of the mining of iron and of its preparation for smelting.
The equipment used includes diamondbit rotary drills, hydraulic shovels and loaders, water wagons, production trucks and heavyduty conveyors. India as a 4th steel producer in the world has resulted due to adaptation of new technologies in the field of iron and steel making since from the last few decades. Blast furnace simulation download ebook pdf, epub, tuebl. Aug 04, 2011 the purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. In this period, lots of metallurgical enterprises got a new cognition on blast furnace ironmaking technology. Till 1990, the blast furnace route of ironmaking had about 97% 527mt share of global iron production. An introduction 3rd the book focuses on the control of the blast furnace. How pig iron is converted into iron and steel in blast. The iron ore concentrate is now mixed and ready for the pelletizing process. Blast furnace ironmaking an overview sciencedirect topics. Silicon and aluminum often occur in iron ores as quartz, aluminum silicate clay minerals, or gibbsite. Chemistry extraction of iron in blast furnace egogy youtube. T, burla person involved name designation and email. 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.
Blast furnace ironmaking process with superhigh tio 2 in. Presentation at edrc kolkata on 14th feb 2007 by n. Non blast furnace ironmaking technology process is currently a supplementary system, and. 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 purpose of a blast furnace is to reduce the concentrated ore chemically to its liquid metal state. This book describes the principles of the blast furnace process and especially the control of the process. Combustion in an ironmaking blast furnace abstract in order to understand the complex phenomena of pulverized coal injection pci process in blast furnace bf, mathematical models have been developed at different scales. 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 ore is usually a mixture of iron and vast quantities of impurities such as sand and clay referred to as gangue. With modern blast furnace ironmaking an introduction the reader has a compact compendium of the blast furnace process available. Blast furnaces are used to produce pig iron from iron ore for subsequent. Therefore, the probability density function pdf is introduced to completely describe the modeling errors in both time scales and space scales.
Iron ores with lower iron content such as taconite are first processed to concentrate the iron level and drive off volatile impurities. The iron found in iron ores are found in the form of iron oxides. 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. In this process carbon is needed for the reduction of the iron ore. The ironmaking process centers on the blast furnace, which produces molten pig iron, and also includes the sintering machine, which produces sintered ore as a raw material for the blast furnace, coke ovens that produce coke, which is important as a reducing agent, and hot. Alternative methods known as direct reduction are used in over a score of countries, but less than 5 percent of iron is made this. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. In fact, they are basically the forerunner to modern conventional last blast furnaces and hence they have operated for a longer. Your challenge the conventional blast furnace route is too costly and energyintensive to keep pace with dynamic market changes, where even short and. The ore part of a charge consists of iron ores and concentrates, manganese ores and various types of scrap containing iron. All the three ingredients are crushed into small round pieces and mixed and put on a hopper which controls the input.
Iron is made by reacting iron ore iron oxide and impurities, coke a reductant and limestone caco 3 in a blast furnace. 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. 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. Analysis of the alkali flow in ironmaking reactors by a thermochemical approach. It may have potential for application in the blast furnace ironmaking process with superhigh 80 pct vanadium titanomagnetite. Present day ironmaking technology has evolved over many years through innovations in raw materials preparation, blast furnace design and blast furnace practice. The tapped product liquid hot metal is equivalent in quality to the hot metal produced in a blast furnace or corex plant. Analysis of the alkali flow in ironmaking reactors by a. Alternative ironmaking processes compete with the blast furnace process route. Pdf iron and steel making is one of the most intense energy consuming in the industrial sectors.
The blast furnace has been and will remain the centrepiece of integrated facilities in the steel industry. The rhf is the process reactor which consists of a flat, refractory hearth rotating inside a stationary, circular tunnel kiln. The dri fines are processed to hotcompacted iron, transferred to a charging bin positioned above the melter gasifier and then charged into the melter gasifier, where melting takes place. The novel flash ironmaking process uses gaseous reducing agents such as natural gas, hydrogen, other syngas or a combination thereof. This book describes the blast furnace process for operators. Extraction of iron in a blast furnace reduction haematite o. Mar 02, 20 the temperature regime in the blast furnace shaft is such that it can be assumed a zone of mixedcontrol exists. Iron and steel making is one of the most intense energy consuming in the industrial sectors. The no 6 blast furnace produces around 7,300 tonnes of molten iron per day. 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. Design of blast furnace is evolved through experience. Modern developments in blast furnaces, including modelling and process control are discussed along with an introduction to the alternative methods of ironmaking. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. Recent progress in ironmaking technology for 2 mitigation.
Shows how iron ore, limestone, and coke are handled and prepared for the blast furnace in the making of iron. Nov 22, 20 blast furnace, co, reaction, slag, chemistry of the ironmaking by blast furnace process. Based on it, a novel wavelet neural network wnn modeling method is proposed by minimizing the twodimensional 2d pdf shaping of modeling errors. The production of iron from its ore involves an oxidationreduction reaction carried out in a blast furnace. In the area of steelmaking, bof plant practice including pretreatment of hot metal, metallurgical features of oxygen steelmaking processes, and their control form part of the book. Pdf technological changes in blast furnace iron making in. Creating steel from lowgrade iron ore requires a long process of mining, crushing. These alternative routes can be classified into the direct reduction methods producing the direct reduced iron dri, and the smelting reduction methods producing the liquid hot metal. These furnaces are ideally suited for small scale operations.
However, the proportion of blast furnace bf basic oxygen furnace bof steelmaking could drop to 40 % in 2050 from the current level of 60 % as the blast furnace ironmaking proportion falls from around 95 % to 60 % of the total iron ore processed. Sudheer steel making value chain steel making flow line steel making flow line finishing history and evolurtion what is iron making. Us5395441a revert briquettes for iron making blast furnace. Introduction of high quality coke to a blast furnace will. Optimum nut coke for the iron making blast furnaces. Blast furnace iron has limited engineering applications. Robust descriptions of the main equipment and systems, process technologies and best practices used in a modern blast furnace plant are detailed. The proposed technology is to be applied to the production of iron as a feed to the steelmaking process, eventually replacing the blast furnace and other alternative ironmaking processes. Prepared for mcmaster blast furnace ironmaking course, may 1116, 2014 abstract. 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. Improvements in blast furnace operation usually have. Iron fe is a relatively dense metal with a silvery white appearance and distinctive. The large, refractory lined furnace is charged through its top with iron as.
Kobe steel started operation as an integrated steel manufacturing. 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. This paper also describes future developments in blast furnace iron making. The main objectives of this project were higher blast furnace output, achievement of a maximum campaign length and increased effective hot metal production.
The blast furnace, the most important hot metal producer, has improved over the years and continues to do so. Milestones of our blast furnace operation technologies tamura categorized our history of pig iron making into the following three periods, in an article. Analysis, control, and optimization uses a fundamental first principles approach to prepare a blast furnace mass and energy balance in excel. The intensive utilization of fossil carbon in the ironmaking blast furnace bf is related directly to co2 emission and global warming.
Blast refers to the combustion air being forced or supplied above atmospheric pressure. 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. Chemistry of the ironmaking by blast furnace process ispatguru. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. 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.
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. As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. Blast furnace iron making raw materials blast furnace reaction. The most important chemical properties are moisture, fixed carbon, ash, sulfur, phosphorus, and alkalies.
Modern blast furnace ironmaking 3rd edition pdf ammedicine. In lecture 31 a simplified material balance is considered for ironmaking blast furnace and the results of material balance formulation are presented in the form rist diagram in that it is considered that charge consists of pure iron oxide and coke and the product is hot metal containing carbon only. Ironmaking and steelmakingtheory and practice and hot metal production by smelting reduction of iron oxide both published by phi learning as well as two other books entitled beyond the blast furnace and metallics for steelmakingproduction and use besides a number of monographs on cokemaking. Mini blast furnaces mbf are generally viewed as miniature versions of the conventional large blast furnaces bf. Silicon and aluminum often occur in iron ores as quartz. Modern blast furnace ironmaking anintroduction withcontributionsfrom renardchaigneau timvander jenniferwise second edition, 2009.
Pdf optimum nut coke for the iron making blast furnaces. Analysis, control and optimization uses a fundamental first principles approach to prepare a blast furnace mass and energy balance in excel. 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. Modern blast furnace ironmaking an introduction pdf. Now there are nearly 700 blast furnace available in world. A suitable slag composition was found to satisfy the smelting process in a blast furnace with superhigh tio2 content at low temperature by using more mgo and less cao content. Extraction of iron metallurgy blast furnace and reactions. Amongst all the ironmaking processes, the blast furnace technology, which has been around the longest, still holds the dominant position. An iron making blast furnace revert briquette composition including finishing mill scale, steelmaking slag, blast furnace dust and a binder wherein the binder includes portland cement, granulated blast furnace slag cement or mixtures thereof and bentonite. The blast furnace is the most prolific of the metallurgical furnaces operating in the world. The blast furnace gas bfg generated in the bf is cleaned through a series of steps primary cleaning at dust catchercyclone and secondary cleaning at. Ironmaking 101 from ore to iron with blast furnaces. Operating line prediction of corex ironmaking process. Ironmaking in rotary hearth furnace ironmaking in the rotary hearth furnace rhf is a direct reduction process which utilizes noncoking coal for the reduction of iron ore.
Elements like potassium and sodium have a negative impact on the blast furnace performance. Robust descriptions of the main equipment and systems, process technologies, and best practices used in a modern blast furnace plant are detailed. The bentonite improves the cold and hot strength of the briquette. It is mainly for use for iron castings, and for abrasion resistance and heattransfer applications. A blast furnace charge consists of ore, fluxes and fuel. Flash ironmaking process 20170807 industrial heating. 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 making mm15020 5th sem b tech department of metallurgy and materials engineering v. It is in the blast furnace that extraction of iron occurs. Modeling error pdf optimization based wavelet neural. Milestones of our blast furnace operation technologies tamura categorized our history of pigiron making into the following three periods, in an article. Smelting reduction of oxide ores with carbon as a reducing agent. 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 performance of ironmaking blast furnace can be characterized in different ways.