Modern steel making process uses a blast furnace for manufacturing steel. Jan 28, 2016 the purpose of a blast furnace is to reduce and convert iron oxides into liquid iron called hot metal. Blast furnace gas is a byproduct of blast furnaces where iron ore is reduced with coke into metallic. Blast furnace, coke gas and converter gas for power production. The ore part of a charge consists of iron ores and concentrates, manganese ores and various types of scrap containing iron. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. Furnace process and position of cohesive zone high rates of injection productivity. The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. The figure shows a flowchart of the integrated manufacturing process for iron and steel using the blast furnace and basic oxygen furnace denoted bf and bof hereinafter, respectively, which is presently the most commonly used method 51% of world steel production. Iron is made by reacting iron ore iron oxide and impurities, coke a reductant and limestone caco 3 in a blast furnace. Nov 26, 2012 blast furnace training dvd from the bcsa and tata steel. Blast furnace gas is a byproduct of blast furnaces where iron ore is reduced with coke into metallic pig iron. Blast furnacebasic oxygen furnace uses iron ore as its base raw material that accounts over just 50% of bof steel costs, and electric arc furnace uses scrap as its base that represents around 75% of eaf steel cost.
Ferrous comes from, or contains iron, while nonferrous does not contain iron. One of the most common open hearth processes is the electrical melting process. Primetals technologies has provided blast furnace engineering, project excellence and expertise to customers worldwide for over a century. In steelmaking, impurities such as nitrogen, silicon, phosphorus, sulfur and excess carbon most important impurity are removed from the sourced iron, and alloying elements such as manganese, nickel, chromium, carbon and vanadium are added to produce different grades of steel.
Basic oxygen furnace based steelmaking processes and cleanliness control at baosteel l. Process of blast furnace pdf a blast furnace is a huge steel container many metres high and lined. Steel to restart second blast furnace, create 300 new. The cokemaking process involves carbonization of coal to high temperatures 1100c in. Primary steel making includes converting liquid iron from a blast furnace and steel scrap into steel via basic oxygen steel making or melting scrap steel andor direct reduced iron dri in an electric arc. Principle of iron making by blast furnace by a k biswas download free ebooks online. In a blast furnace, fuel coke, ores, and flux limestone are continuously supplied through. It is suitable for students of metallurgy as well as. Bricks sic grout graphite grout page 16 pt is bf ternium blast furnace no. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. The basic oxygen steelmaking process differs from the eaf is that bof is selfsufficient in energy.
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. 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. Ironmaking 101 from ore to iron with blast furnaces. There have been tremendous improvements in iron and steelmaking processes in the past twenty years. Steelmaking has played a crucial role in the development of ancient, medieval, and modern technological societies. Plant and equipment, metallurgical processes, chemistry, raw materials, products and byproducts, operation, alternative. Feb 29, 2008 modern developments in blast furnaces, including modelling and process control are discussed along with an introduction to the alternative methods of ironmaking.
The manufacture of steel royal institute of chemistry. The blast furnace is a large steel structure about 30 metres high. In new zealand steel is made by bh p nz at glenbrook, where about 90% of new zealands annual steel requirements are produced. Much of this improvement is based on the application of fun. Blast furnace gas has a high carbon monoxide co content and a low heating value. Korfarc process of steel making which is being implemented at ushamartin with installation of a 215 cu. Production of pig iron in a blast furnace 9 scheme of a blast furnace content a blast furnace charge and its treatment a blast furnace charge consists of ore, fluxes and fuel. As the mixture of iron ore, coke and limestone heats, the hot waste. Calculation of blast furnace size is empirical in nature.
Incidents happening in the blast furnace will strongly affect the stability and smoothness of the ironmaking process. Basic oxygen steelmaking bos makes steel from blast furnace iron and small amounts of scrap metal. 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. So at the same time thyssenkrupp steel is also planning to gradually convert its blast furnace ironmaking to the direct reduction dr path. Slag and blast furnace gas are formed in the blast furnace. Pdf technological changes in blast furnace iron making in.
Steel plant iron making blast furnace start completion location client capacity the 2nd relining project of no. Jsw steel ltd is an integrated steel plant of 38 mtpa capacity, with two corex and two blast furnace bf units for producing hot metal. 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 iron making is the main method for modern steel production,the process of blast furnace is an important part. These other ores are usually first roasted to convert them into the oxide. The mixture of scrap and hot metal can vary from all scrap to all hot metal, but a halfandhalf mixture is most common. This concentrated ore is mixed with limestone caco 3 and coke and fed into the blast furnace from the top. They have thick steel sides, lined with refractory bricks, to ensure that heat is not lost.
Principal concepts of physical chemistry useful in steel making are. Below is a picture that displays a simplified version of the bos process. The blast furnace module is part of the steel manufacturing course. Learn more who are renowned for creating steel using a blast furnace process and very short step from the blast furnace. Most blast furnaces are linked to a basic oxygen steel plant, for which the hot metal typically contains 4 to 4. The blast furnace is a huge, steel stack lined with refractory brick. With design, manufacture and installation of pig iron, ferromanganese smelting blast furnace, sinter plant, hot air stove, cip system, shaft furnace, lime kiln, etc. 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. Two large blast furnaces that began their operation in 2009 and 2011 respectively. 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. Describes the principles of the blast furnace process and especially the control of the process. This book focuses on the control of the blast furnace process with respect to thermal control, gas flow control and casthouse operation. The metallic iron produced by such a furnace contains a relatively high proportion of. Owater channel isolated stave gets hotter oeventually furnace shell gets hot and cracks occur nonfixed connection stave moves.
A typical blast furnace may be up to 32 metres in height and 10 metres in diameter. Proposed rule for mandatory reporting of greenhouse gases. Hot metal from the blast furnace is added by pouring from a ladle through a trough positioned in the door. 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. It is suitable for students of metallurgy as well as for blast furnace operators and management. The furnace gets its name from the method that is used to heat it. Process monitoring of ironmaking process in a blast furnace. It is in the blast furnace that extraction of iron occurs.
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. Technical support document for the iron and steel sector. Jul 25, 2007 blacksmithing part 1 forging an iron bloom into new iron bars. Basic oxygen furnace based steelmaking processes and. This guideline of safety is applicable to blast furnace dept. It is a group of bodies which interact with each other and can be isolated, either mentally or physically, from the surroundings ex. Thus far, diagnosis of abnormalities in furnaces still mainly relies on the personal experiences of individual workers in many iron works. Steelmaking is the process of producing steel from iron ore andor scrap. The hot metal from the blast furnace contains up to 4. Early processes of steel making were made during the classical era in ancient iran, ancient china, india, and rome but the process of ancient steelmaking was lost in the west after the fall of the western roman empire in the 5th century ce. The iron and steel industry in the united states is the third largest in the world after china and japan, accounting for about.
Preheated air at about o c is blasted into the furnace through nozzles near its. Firing blast furnace gas without support fuel in steel mill boilers. Modern developments in blast furnaces, including modelling and process control are discussed along with an introduction to the alternative methods of ironmaking. Steelmaking reduces the carbon content to a level that matches the customers requirements. Blast furnace training dvd from the bcsa and tata steel. Firing blast furnace gas without support fuel in steel.
Steel to restart second blast furnace, create 300 new jobs. Productivity and coke rates in the blast furnace and the ability to refine steel to demanding specifications have been improved significantly. 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. Preheated air at about o c is blasted into the furnace through nozzles near its base the largest blast furnaces in the uk. In the blast furnaces bf liquid iron popularly termed as hot metal is produced by the process of reduction at high temperature from raw materials like iron ore, base mix, sinter, pellet, coke, fluxes limestone, quartzite, dolomite.
Iron ores with lower iron content such as taconite are first processed to concentrate the iron level and drive off volatile impurities. Operating experiences with corex and blast furnace at jsw. In the blast furnace route bf pig iron is extracted from iron ore using coke. Thomas4 optical microscopy, total oxygen measurements and slime tests have been conducted to quantify. Members of usw local 50 operate the blast furnaces and coke mill, while. These revision notes on the extraction of iron in a blast furnace and the process of steel making and other alloys should prove useful for the new aqa, edexcel and ocr gcse 91 chemistry science courses. Blast refers to the combustion air being forced or supplied above atmospheric pressure. The purpose of a blast furnace is to reduce and convert iron oxides into liquid iron called hot metal. Pdf technological changes in blast furnace iron making. Some examples of ferrous metals would be mild steel, cast iron, high strength steel, and tool steels. Iron ore, coke and limestone are put into the top, and preheated air is blown into the bottom. It is lined with refractory firebricks that can withstand temperatures approaching 2000 o c. Now there are nearly 700 blast furnace available in world. It has started its integrated steel plant operation with.
Blast furnace smelting equipment sinter plant lime. Extraction of iron metallurgy blast furnace and reactions. The metal hot metal blast furnace ironmost blast furnaces are linked to a basic oxygen steel plant, for which the hot metal typically contains 4 to 4. Scrap is charged to the furnace through doors in the furnace front. This module introduces the learner to the operation of the blast furnace for the transformation of iron ore to molten iron. 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 furnaces are used to produce pig iron from iron ore for subsequent. Incidents happening in the blast furnace will strongly affect the stability and smoothness of the iron making process. Blast furnace smelting equipment sinter plant lime kiln. Blast furnace basic oxygen furnace uses iron ore as its base raw material that accounts over just 50% of bof steel costs, and electric arc furnace uses scrap as its base that represents around 75% of eaf steel cost. Blacksmithing part 1 forging an iron bloom into new iron bars.
Blast furnace products and there use size of blast furnace design of blast furnace is evolved through experience. 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. How steel is made using the basic oxygen steelmaking process. Rather than molten pig iron, dr plants produce sponge iron direct reduced iron, dri which is then processed into crude steel in electric arc furnaces. 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. Process monitoring of ironmaking process in a blast.
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