Valia, scientist, ispat inland inc introduction a world class blast furnace operation demands the highest quality of raw materials, operation, and operators. The important zones that smelt iron ore are described starting from the blast furnace hearth and working upward. The forging furnace is used for preheating billets and ingots to attain a forge temperature. In a blast furnace, iron ore reacts with hot coke to produce pig iron. Reverberatory furnace, in copper, tin, and nickel production, a furnace used for smelting or refining in which the fuel is not in direct contact with the ore but heats it by a flame blown over it from another chamber.
The length of the furnace body can vary dramatically depending on the application, however, it becomes harder to maintain a uniform temperature throughout the chamber the longer the furnace. Blast furnace is a counter current heat and mass exchanger in which reduction and smelting of metallic mineral takes place. The burden charge consisting of iron oxide, flux and coke and it provides through the throat from the top of the furnace. The period of the blast furnace operation is limited by the life of the furnace hearth life. Blast furnaces used in the isp have a more intense operation than standard lead. Working height of the furnace it is the vertical distance between the centerline of the tuyeres and the stockline. Forging furnaces use an open fireplace system and most of the heat is transmitted by radiation. 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. Development of mathematical model of blast furnace1115kb. Modeling of burden distribution in the blast furnace doria. When a larger amount of coke exists, relatively, at the center of a blast furnace, the high temperature gas, consisting mainly of co generated at the tuyeres.
The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. Jul 12, 2019 blast furnace and process description. Induction furnace capacities range from less than one kilogram to one hundred tonnes, and are used to melt iron and steel, copper, aluminium, and precious metals. So today we discuss the working principle of cupola furnace as well as see the construction, advantages, disadvantages, and applications of cupola furnace. Comparative performance evaluation of blast furnace. The cleaned blast furnace gases are used to preheat stoves and boilers within the steel plant. Blast furnaces are similar to furnaces, but can smelt only ore blocks and toolsarmor made of iron, gold or chainmail. The principle of blast furnace operational technology and. In steelmaking, this process, now largely obsolete, is called the openhearth. 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.
Blast furnace bleeder valve operation download pdf info publication number us3216819a. The furnace body in a rotary furnace is generally made from steel plate and welded to form the barrel, which can be up to 230 m in length. And a piece of good news at the end of the article we have two surprises, one is i give you the pdf of this article and the second is a quiz on cupola furnace for practice. A brief summary of the history and archaeology of this early 18th century charcoal blast furnace, planned in 17 by abraham darby of coalbrookdale and managed between 1714 and 1736 by john kelsall, the wellknown quaker. These improvements to the processing of scrap steel comprised of larger more efficient and higher capacity furnaces. 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.
Glossary of terms used for a blast furnace ispatguru. Pdf using blended learning method, blast furnace subject was. 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. Pdf technological changes in blast furnace iron making. Tech, metallurgy and materials engineering of national institute of technology, durgapur, during the academic year 202014 and it has found worthy of acceptance. The furnace temperature is maintained at around 1200 to 1250 oc. A major advance in bf ironmaking has been the use of pulverized coal which partially replaces. A cross section of a blast furnace showing nomenclature of different portion is shown in fig 1. Oct 04, 2016 blast furnace extraction of iron from blast furnace class 12 ncert chemistry blast furnace working animation extraction of iron metallurgy of iron. Converter gas, which is produced whenever carbon is extracted from pig iron in the converter plant by. Mini blast furnaces mbfs are ideally suited to small scale operations. Whitfield, peter, design and operation of a gimbal top charging system pdf, archived from the original pdf. Process analysis for blast furnaces by the discrete element method.
What is the working principle of an electric arc furnace. These models have been used for the analysis and the opera tion design of actual operation. Us3216819a us37640a us3764060a us3216819a us 3216819 a us3216819 a us 3216819a us 37640 a us37640 a us 37640a us 3764060 a us3764060 a us 3764060a us 3216819 a us3216819 a us 3216819a authority us united states prior art keywords valve body gas tappet gases prior art date 19600621 legal status the legal status is an assumption and is not a legal conclusion. The cupola can be made of any size and the size of the cupola is measured in diameters which range from 1. Agglomeration techniques with sintering and pelletising in details. This box is connected to the furnace blower pipe known as the blast pipe. Since mbfs are small working volume ranges between 100 370 m3. A packed bed in a blast furnace is sup ported by the formation. Stateoftheart computational fluid dynamics model optimizes fuel rate in.
In a blast furnace, fuel coke, ores, and flux limestone are continuously supplied through. Certificate this is to certify industrial training work entitled detail study of working in blast furnace area vizag steel plant that is submitted by arijit karmakar 12mme29, student of 2 nd year,b. Calculation of blast furnace size is empirical in nature. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals. In such cases dual fuel fired boiler is more effective from economic and environment point of view. Blast furnace is currently unusable as a result of. The working of electric furnace includes charging the electrode, meltdown period melting the metal and refining. The blast furnace bf is the most widely used ironmaking. 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 agglomeration and pelletization of iron ores requirements to individual components of a blast furnace charge time for the study. The working principle of water tube boiler is very interesting and simple. 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 heavy and light scrap in the large basket is preheated with the help of exhaust gas.
Blast furnace is currently unusable as a result of widespread crashing for the past few days, a small number of users has been consistently crashing the two major blast furnace ccs donationbf and truebf, as well as world 358 by taking over the pump and overheating the furnace. The ore part of a charge consists of iron ores and concentrates, manganese ores and various types of scrap containing iron. Production of pig iron in a blast furnace 9 scheme of a blast furnace content. Blastfurnace gas, for example, which occurs as a byproduct inside the blast furnace and is used as a fuel gas for heating up the blastheating systems to generate hot air, contains twenty to twentyfive percent carbon monoxide. 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. The blast furnace is a huge, steel stack lined with refractory brick. 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.
Coke is the most important raw material fed into the blast. Blast furnace and process description chemical engineering. Optimizing blast furnace operation to increase efficiency. Pdf technological changes in blast furnace iron making in. The second world war saw a steep increase in the use of these furnaces leading to the modern electric arc furnace design operation and working principles. The furnaces were of the steam, hot blast coke type, constructed entirely of stone and rectangular in shape. For the past few days, a small number of users has been consistently crashing the two major blast furnace ccs donationbf and truebf, as well as world 358 by taking over the pump and overheating the furnace.
A wooden charging bridge extends from a bluff to a charging hole at the top of the chimney stack. Chemistry elements lying at top of reactivity series are more reactive than elements lying below them in series. Forthis purpose the mathematical model of a blast furnace has been used szargut, 1983. Stoves absorb heat from the combustion of blast furnace gases with air and transfer this heat to the air blast that will be injected into the blast furnace tuyeres. The inside of the original furnaces were lined with firebrick which was imported from england. The identification of the influence of the working parameters of the blast furnace upon the net calorificvalue of bfgas is of great practical importance from the point of view of energy management of ironworks. The blast furnace 1 the blast furnace by chan, sam and elly 2 what is a blast furnace. The shape of the cupola is cylindrical and the equipment is arranged in the vertical fitted with doors. A blast furnace charge consists of ore, fluxes and fuel. Kobe steel started operation as an integrated steel manufacturing company with the blowingin of the no. Sintering or pelletising improves the blast furnace operation and reduces energy consumption. A blast furnace is a special type of furnace for smelting iron from ore.
All the three ingredients are crushed into small round pieces and mixed and put on a hopper which controls the input. Fuel is also used at double the rate of regular furnaces. As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. Now there are nearly 700 blast furnace available in world. Principle,construction, working, advantages, disadvantages and application january 6. A blast furnace also represents a huge overhead cost because, once fired up, it typically runs for six to 10 years, giving an operator little flexibility. Owater channel isolated stave gets hotter oeventually furnace shell gets hot and cracks occur nonfixed connection stave moves. The refractory materials applied in the furnace hearth.
It was the smelting unit where raw materials were transformed into molten iron. They can be up to 60 metres 200 ft tall and 15 metres 49 ft in diameter. Jan 06, 2018 cupola furnace is a melting device used to melt cast iron, niresist iron, and some bronzes and it is used in foundries. The advantage of the induction furnace is a clean, energyefficient and wellcontrollable melting process compared to most other means of metal melting. 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. Blast furnace extraction of iron from blast furnace class 12 ncert chemistry blast furnace working animation extraction of iron metallurgy of iron. Electric arc furnace design operation and working principle. Blast furnaces bfs are a critical part of the manufacturing procedure for the largescale integrated iron and steel industry and have working principles totally. The typical load is 5 to 6 ton with the furnace operating for 16 to 18 hours daily. Blast furnace is currently unusable as a result of widespread crashing. The advantage of the induction furnace is a clean, energyefficient and wellcontrollable melting process. The purpose of a blast furnace is to reduce and convert iron oxides into liquid iron called hot metal.
The analysis shows the preference of students to work with different. Pdf as a promising method to strengthen the blast furnace smelting and to realize reduced fuel operation, highproportion pellet charging has. Air which supplies the oxygen necessary to burn the fuels forced through the cupola by a blower. And a piece of good news at the end of the article we have two surprises, one is i give you the pdf of this article and the second is a.
The blast furnace at saugus iron works national historic site. Jan 08, 2017 when i am working in pearson, i worked on this project 2. Alumina refractories these refractories are used for lining of blast furnace. Iron blast furnace is a vertical shaft, which is used to melt the iron ore and to produce hot metal by heat exchange and chemical reaction. For those that arent familiar with the mechanics of the blast. Extraction of iron metallurgy blast furnace and reactions. 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. Working toward technology demonstration the ulcosbf developments in europe ir. This doctoral dissertation is the result of my research work carried out at the thermal and flow. Hot blast stoves supply hot blast after heating cold air provided by turbo blowersfans to blast furnace through hot blast main, bustle main, tuyere stocks and tuyeres. Nov 27, 2011 the optimal working height of blast furnaces in smelting titanomagnetite sinter and pellets is 10. Creating steel from lowgrade iron ore requires a long process of mining, crushing.
Optimizing blast furnace operation to increase efficiency and. Aug 04, 2011 the purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. Stoves are also provided with waste heat recovery system and coke oven gas enrichment facilities, if coke oven gas is available. Pdf blast furnace performance under varying pellet proportion. Annular space it is the difference between the stock line radius and the large bell radius. The optimal working height of blast furnaces in smelting titanomagnetite sinter and pellets is 10. Blast furnaces are used to produce pig iron from iron ore for subsequent. Air heated in the blast furnace stoves, is applied from the bottom of the. Once an item and a fuel are placed into the blast furnace, the block state changes to lit and the item is smelted twice as fast as a regular furnace.
Coke production for blast furnace ironmaking by hardarshan s. The iron ore concentrate is now mixed and ready for the pelletizing process. The coke layer has a gasflow resistance smaller by a factor of 10 compared to that of the ore layer and has a high gaspermeability. In the furnace, hot metal along with slag is processed from the raw material which gets collected in the hearth and blast furnace gases come out of blast furnace from the top. Oct 11, 20 glossary of terms used for a blast furnace. In earlier days, blast furnace bf top used to be open with the gas from the furnace escaping into the atmosphere and burning, causing environmental issues while wasting considerable energy. Blast furnace an introduction blast furnace is the focus of any integrated steel plant. Temperature at lean blast furnace top gas operation. A wind box cast iron encircles to the outside of the furnace bottom. Blast furnace gas, for example, which occurs as a byproduct inside the blast furnace and is used as a fuel gas for heating up the blast heating systems to generate hot air, contains twenty to twentyfive percent carbon monoxide. 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. Blast furnace is currently unusable as a result of widespread. By 1850 as the furnace size increased, the furnace top could be. When i am working in pearson, i worked on this project 2.
A blast furnace is usually built with a steel case and bricks made of. We work closely with subcontractors and construction companies to minimise the impact of major work on ongoing operations, the outofoperation or. This is to certify that the project report entitled blast furnace, being submitted by suraj kumar vishwakarma of dit university to tata steel, as a part of summer training course of b. The furnaces were of the steam, hotblast coke type, constructed entirely of stone and rectangular in shape.
The blast furnace is a countercurrent reactor where rising hot gases heat and chemically reduce iron oxides in the descending charge materials. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. Blast furnace operation an overview sciencedirect topics. Alumina content of refractories varies depending on in which zone of the blast furnace they are used for lining. By 1850 as the furnace size increased, the furnace top could be closed. 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 charge, which consists of iron ore, coke and limestone etc. Introduction blast furnace is the mostly applied facility for the pig.
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