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. Just a hole in the ground with some charcoal and a pvc pipe leading into one side of it. View and download ussc hotblast 1500 owners manual online. Describes the principles of the blast furnace process and especially the control of the process. A blast furnace is a type of furnace for smelting whereby the combustion material and ore are supplied with air from the bottom of the chamber such that the chemical reaction does not take place only at the surface. High temperature top combustion hot stoves of kalugin. The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal.
Burden materials consisting of iron ore, coke or charcoal used as a reducing agent as. Mini blast furnace blast furnace is the most popular route to produce molten iron for steelmaking. Several companies in the region have announced that they are going to construct their first blast furnace. The entire life of a blast furnace operator is spent to achieve the following aims. So i decided to build this small portable cupola furnace to do just that. Blast furnace an introduction blast furnace is the focus of any integrated steel plant. 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. High temperature top combustion hot stoves of kalugin design. So it was only a matter of time before i set out to melt iron. Analysis of synthetic natural gas injection into charcoal blast furnace. If you scroll past the diagram you can read about the blast furnace process. Media in category drawings of blast furnaces the following 127 files are in this category, out of 127 total. Mar 06, 2016 introduction and construction blast furnace.
Admitting a loss of 5%, remaining 50% available for others purposes normally utilized to generate electric power about 180 kwh per ton of produced pig iron. Pfr for increasing the production capacity of blast furnace. 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. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. In mexico, growth has come predominantly from the integrated minimill route, production of dri followed by eaf melting.
Blast refers to the combustion air being forced or supplied above atmospheric pressure. With modern blast furnace ironmaking an introduction the reader has a compact compendium of the blast furnace process available. Its flexibility allows the burdening from 100% lump ore to any blend of lump. The top countries of suppliers are india, china, from which the percentage of mini blast furnace supply is 6%, 93% respectively. The small bell then closes, to seal the blast furnace, while the large bell rotates to provide specific distribution of materials before dispensing the. The blast furnace is a hightemperature, pressurized countercurrent reactor with dynamic process conditions.
This book includes a set of equations that accurately describe stoichiometric and enthalpy balances for the process and which are consistent with observed. While gasbased as well as coalbased dri production routes produced 2. The authors have very extensive experience as operators as well as consultants to many steel plants worldwide. The charge, which consists of iron ore, coke and limestone etc. A blower is set up to provide large amounts of air through the pvc p. The mini blast furnace mbf is a very flexible and competitive equipment, suitable for both basic and foundry grade hot metal production, in the range of 80. Theory and practice presents theoretical, experimental, and operational evidence about the iron blast furnace as well as a mathematical description of its operation. A major advance in bf ironmaking has been the use of pulverized coal which partially replaces. Battery cutting machine,plastic container chips making crusher and washing tank. The principle of blast furnace operational technology and. The process indices of mini blast furnace are similar to that of a conventional blast furnace.
A wide variety of mini blast furnace options are available to you, there are 129 suppliers who sells mini blast furnace on, mainly located in asia. After awhile a guy like me get tired of just melting aluminum. Since mbfs are small working volume ranges between 100 370 m3. Facilities available at blast furnace shop of rsp rourkela steel plant has 4 nos. Sinter is produced from fine raw ore, small coke, sandsized limestone and numerous other steel plant waste materials that contain some iron. Therefore, this section is included as an introduction chapter, we can say as a refresher. The blast furnace back to how the plant works introduction the purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. Temperature of a blast furnace the physics factbook. Blast furnace gas is a byproduct of blast furnaces and is produced by the reduction of iron ore to metallic iron. Pdf design of blast furnace crucibles by means of the nodal. Feb 17, 2015 just a hole in the ground with some charcoal and a pvc pipe leading into one side of it. Iron and steel sector information sectorbased information and. 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.
Pfr for increasing the production capacity of blast. Mini blast furnace mbf is the most proven technology, as revealed by one recent global iron production data. The blast furnace is a huge, steel stack lined with refractory brick. This book focuses on the control of the blast furnace process with respect to. To increase the productivity of blast furnace as high as possible. A preheated air is blasted into the furnace and after a series of reaction, molten pig iron is produced.
Although the space available in the existing site was not adequate for storing large quantities of raw materials, the balst furnace along. In general, blast furnaces energy requirement constitutes 70% of overall iron and steel production process and this amount almost equal to 50. Working volume of mini blast furnaces range from 100m3 to 500m3, with production ganging from 60,000 tpa to 375,000 tpa. Two large blast furnaces that began their operation in 2009 and 2011 respectively. 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. Blast furnace definition of blast furnace by merriamwebster. As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed.
How a blast furnace works scotlands brick manufacturing industry. Reduced power consumption when compared to classical blast furnace 6. Blast furnace is the focus of any integrated steel plant. Blast furnace operation an overview sciencedirect topics. In order to study the effect of replacement of granular charcoal and injection of pulverized charcoal the well known blast furnace five fluid model bfffm is. Ieaghgiets iron and steel industry ccus and process integration workshop, tokyo, japan, 4 7 november 20. The mini blast furnace has been constructed in the existing mini steel complex adjacent to the steel melting shop in order to facilitate easy hot metal handling by transfer cars as shown in figure2. A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. X 173m3 working volume were installed and commissioned prior to 1994. 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. Blast furnace gas consists of about 4560% nitrogen.
Smallvolume blastfurnaces the future of blastfurnace. The products from mini blast furnaces are of the same quality as that of normal blast furnaces and are free of tramp elements this is of particular advantage in steel making in mini steel plants 5. Blast furnace products and there use size of blast furnace design of blast furnace is evolved through experience. To decrease the coke rate as low as possible to produce unit ton of hot metal. Table 1 typical sulphur balance in different materials sulphur input sulphur output material kg. Because of its high nitrogen content, blast furnace gas has a very low heat. Mini blast furnace slrm is operating a 262 m 3 working volume blast furnace since 2012. 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. Mini blast furnaces mbf are generally viewed as miniature versions of the conventional large blast furnaces bf. In a bof, molten iron from the blast furnace is combined with flux and scrap steel where highpurity oxygen is injected. Ironmaking blast furnaces consist of several zones. Mini blast furnaces mbfs are ideally suited to small scale operations. Please practice handwashing and social distancing, and check out our resources for adapting to these times.
A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals. But, conventional blast furnace is capital intensive, solely dependent on good quality metallurgical coke, the gestation period is longer, and requires elaborate burden preparation. 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. Typically this is used for the production of pig iron from iron ore. In addition to this there is a sinter plant having annual production capacity of 635,500 tonnes along with a pig casting. Overall process of blast furnace is given in figure 1. The following overview provides basic information necessary for a proper understanding of the problem of heat transfer. Ascending oxygen in the air reacts with the carbon in the coke to form co which reduces the descending iron oxide. Optimizing blast furnace operation to increase efficiency.
Pfr for increasing the production capacity of blast furnaces by 58000 tpa page 3 1. Blast furnaces may have the following ancillary facilities. The formation of iron and steel the blast furnace 2. Stateoftheart computational fluid dynamics model optimizes fuel rate in. We had expected that no new blast furnaces would be built in the developed world.
Calculation of blast furnace size is empirical in nature. High temperature top combustion hot stoves of kalugin design for blast furnaces b. Mbf is a vertical shaft furnace with a crucible like hearth. By malik mubashir university of the punjab lahore, pakistan 2. The purpose of a blast furnace is to reduce and convert iron oxides into liquid iron called hot metal.
We will briefly trace the evolution of coal and oil formation and discuss the links between coals and kerogen macerals through terrestrial. 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. Production of sg grade pig iron in mini blast furnace. Blast furnace sizing considerations for incredible india. These aggregates increased the productivity and therefore proved the economic benefit of the blastfurnace. Air heated in the blast furnace stoves, is applied from the bottom of the. On the diagram below of the blast furnace, just click on the labels for a more detailed description.
The principal raw materials used in the blast furnace operation consist of. Owater channel isolated stave gets hotter oeventually furnace shell gets hot and cracks occur nonfixed connection stave moves. It can produce quantitative data on highly localized spots of any solid sample, and map elemental distributions over small or. And even bronze can fail to fulfil an inner melting need. Alternatively, minimills produce steel from metal scrap using electric arc. Higher plant availability compared to classical blast furnace 7. The mini blast furnace operates very similarly to the conventional blast furnace, but is more flexible due to its size.
The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and. Blast furnace definition is a furnace in which combustion is forced by a current of air under pressure. The blast furnace bf is the most widely used ironmaking. The fuel utilized to heat the blast air is the proper gas generated in the blast furnace bfg.
How can co 2emission from the blast furnace be reduced. The reduced height of these furnaces allows the use of inferior quality coke and even charcoal. Sinter, calibrated lump ore, limestone, dolomite, quartzite and coke are charged into the mbf from top and hot air is passed from the bottom. 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. Blast furnace, productivity, profile, inner volume, working volume introduction in the steel industry, it is a widely accepted fact that blast furnace productivity rated as e.
Now there are nearly 700 blast furnace available in world. About 45% of the generated bfg total volume is utilized for the blast air heating. 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. Blast furnace is used to reduce the iron ore to iron. The ussr was the world leader in largevolume blast furnace manufacture. In the latter half of the past century blast furnaces with the working volume of 86, 15, 1719, 2002, 2300, 2700, 3200, 5014, 5580 m3 were manu factured.
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