Gupta, pk and kanhirodan, r 2007 a dct based filtering of biomedical images. Salzgitter the process shown above is illustrative only and is not designed to show the steelmaking process in detail. Electric arc furnace steelmaking continuous casting design by cover photo. Blast furnace gas is a byproduct of blast furnaces where iron ore is reduced with coke into metallic pig iron. Steel making is mainly concerned with the removal of these impurities. Iron ore, coke and limestone are put into the top, and preheated air is blown into the bottom. Typically, the specification of steel works requires a hot metal with 0. The blast furnace is a huge, steel stack lined with refractory brick. Blast furnace operation an overview sciencedirect topics.
Jones, nupro corporation courtesy of mannesmann demag corp. I decided to try a slightly different arrangement as per the shops at gary. An analysis of hot spot phenomenon in bof process request pdf. Blast furnaces are used to produce pig iron from iron ore for subsequent. The corex process combines coking plant, sinter plant and blast furnace into a single iron making unit.
The natural gas game changer for several decades, most crude iron for steel making has been processed in coke ovens and blast furnaces cobf see figure 1. Blast furnace iron making is the main method for modern steel production,the process of blast furnace is an important part. Process of blast furnace pdf a blast furnace is a huge steel container many metres high and lined. Which one of the following process of steel making is also known as thomas process.
An allfactors analysis approach on energy consumption for the. Remaking the global steel industry lowercost natural gas and its impacts 3 less expensive, better steel. Process analysis for blast furnaces by the discrete element method flows1. Iron and steel industry in the united states wikipedia. The blast furnace gas bfg generated in the bf is cleaned through a series of steps primary cleaning at dust catchercyclone and secondary. 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.
Brown model as will be denominated throughout this work links the consumption of several steel. The production of high carbon steel directly in bloomery. The most common process is quenching with water, but air or a combination of air and water may be used. Nippon steel has developed dry coal charging processes for cokemaking, such as. The electric arc furnace operating cycle is called the taptotap cycle and is made up of the following. They also operate the edgar thomson works, which is the iron and steel making unit of the mon valley works, which includes three other related plants. In theory, any ore containing iron or iron compound can be called iron ore used for steel making process here we introduce some iron ore. Furnace operations the electric arc furnace operates as a batch melting process producing batches of molten steel known heats. Bof process has been used in steelmaking process because of its high. The carbon cost of slag production in the blast furnace. There are two blast furnaces at bluescope steel s port kembla facility. 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.
Page 5 granulated blast furnace slag is produced by quickly quenching chilling molten slag to produce a glassy, granular product. Iron and steel scrap may be added to both the blast furnace and the basic iron furnace. 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.
Introduction kobe steel started operation as an integrated steel manufacturing company with the blowingin of the no. Iron ores with lower iron content such as taconite are first processed to concentrate the iron level and drive off volatile impurities. Nov 26, 2012 blast furnace training dvd from the bcsa and tata steel. Acid bessemer process basic bessemer process ld process open hearth furnace discuss here. Impact assessment of intermediate processes of steelmaking in. In a further process step, the socalled basic oxygen steelmaking, the carbon is oxidized by blowing oxygen onto the liquid pig iron to. Steel producing sites which use blast furnaces, which make iron which is refined into steel, are termed integrated sites. Generally speaking, energy constitutes a significant portion of production cost, from 20% to 40%, according to the estimation from world steel association 7. It was noted that some processes such as coke oven, blast furnace and steelmaking have. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. Jul 25, 2007 blacksmithing part 1 forging an iron bloom into new iron bars. Report on annual worldwide carbon dioxide emissions from. Optimization of blast furnace parameters using artificial.
Given this, we considered that suitable use of oxidation. 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. The blast furnace is the first step in producing steel from iron oxides. Coke production for blast furnace ironmaking by hardarshan s. Properties and uses of iron and steel slag mf 1826 national slag association. 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. Although most eaf steel makers producing long products, such as rebar and merchant bar, continue to use all scrap, some eaf shops today are supplement ing the charge with other materials for. Blast furnace gas has a high carbon monoxide co content and a low heating value. Iron making is a continuous process and a blast furnace. Blast furnace is the heart of the steel industry as it produces molten pig iron which is the raw material for steel making.
Introduction of high quality coke to a blast furnace will. The production of iron in a blast furnace is a continuous process. About 95% of energy for an integrated steelmaking plant comes from solid fuel mainly coal, 34% from gaseous fuel and 12% from liquid fuel. The advantages in steelmaking include reduction in slopping tendency, flux refactory consumption, oxygen consumption, tap to tap time. Hisarna process is more effective and energyefficient. Where co 2 is released when using coal, hydrogen simply produces steam. Iron making in the furnace usually continues for about ten years before the furnace linings have to be renewed. Introduction to the production of clean steel scielo. Creating steel from lowgrade iron ore requires a long process of mining, crushing. 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. As the worldwide first of several tests, hydrogen has been. Principles of blast furnace ironmaking by ak biswas. 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.
The data is needed in decision making and furnace process optimization. Blast furnace, coke gas and converter gas for power production. Primarily, slag consists of calcium, magnesium, manganese and aluminium silicates and oxides in various combinations. 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. Thus far, diagnosis of abnormalities in furnaces still mainly relies on the personal experiences of individual workers in many iron works. Some examples of ferrous metals would be mild steel, cast iron, high strength steel, and tool steels. It can produce quantitative data on highly localized spots of any solid sample, and. Direct reduction scrap ladle refining electric arc furnace steelmaking iron ore pellets. Coke is the most important raw material fed into the blast. Of 54th jsps meeting on iron making practices, june 2007, new haven, connecticut. Assessment on the effect of unburned pulverized coal on the properties of coke in blast furnace. Low silicon and sulphur operation contributes not only to reduction of the heat required to reduce silica in the blast furnace but also to the cost reduction in the steelmaking process. So far, we have considered how iron is extracted from its ore, principally using the blast furnace.
Electric arc furnace steelmaking continuous casting. Steelmaking process an overview sciencedirect topics. 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. Cognizant that the raw materials used in iron making are granular bodies, tanaka et al. Efficient and environmentally friendly smelting reduction a vai ironmaking technology. Below is a picture that displays a simplified version of the bos process. This module introduces the learner to the operation of the blast furnace for the transformation of iron ore to molten iron. The first blast furnaces appeared in the 14th century and produced one ton per day. Apart from secondary steelmaking process, there is hisarna steelmaking process which goes under primary steelmaking. The metal in the ladle is sent directly for basic oxygen steelmaking or to a pretreatment stage. With design, manufacture and installation of pig iron, ferromanganese smelting blast furnace, sinter plant, hot air stove, cip system, shaft furnace, lime kiln, etc. 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. Ironmaking 101 from ore to iron with blast furnaces.
Even though equipment is improved and higher production rates can be achieved, the processes inside the blast furnace. The traditional way of making steel is a mainly a twofold process. 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. Inside the blast furnace bf the process is very complicated and very tough to model mathematically. This guideline of safety is applicable to blast furnace dept. Annual worldwide carbon dioxide emissions from blast furnace iron ore smelting and coke making abstract the 2015 worldwide co2 emissions from blast furnace iron smelting, and associated coke making and ancillary activities came to 2. Presentation will help to provide basic principle and brief overview of iron making to steel making process. Carbonization of coke well graded coal is selected heated or carbonized to coke heated coal is cooled and proper coke are fed into the blast furnace for the farther process. Blast furnace economics are such that larger units have lower unit production costs, hence there has been a trend to bigger and bigger furnaces. Pdf design of blast furnace crucibles by means of the nodal. Feb 25, 2016 basic oxygen furnace bof steel making or basic oxygen furnace steelmaking bos or linzdonawitzverfahren steelmaking or the oxygen converter process is a method in which both molten pig iron and steel scrap are converted into steel with the oxidizing action of oxygen blown into the melt under a basic slag. Cisdi is capable of providing technical services covering the entire ironmaking process. The scrapbased steelmaking is often highlighted as the future. This takes place in a blast furnace by a thermochemical process known as reduction.
Molten pig iron sometimes referred to as hot metal from a blast furnace is poured into a large refractorylined container called a ladle. The process of increasing the carbon content in a low carbon steel and converting it to a high carbon steel. Plant and equipment, metallurgical processes, chemistry, raw materials, products and byproducts, operation, alternative. How pig iron is converted into iron and steel in blast. Soon well be using hydrogen as a reducing agent in the blast furnace instead of carbon, says dr. October 10, 2017 figure 1 drawing of an ironmaking blast furnace with hot blast stove. The basic oxygen steelmaking process is as follows. Ironmaking,blast furnace,china steelmaking,steel business. The blast furnace module is part of the steel manufacturing course. A short video clip illustrating the process of iron and steel making that can be viewed online by students or downloaded for showing in class. Gupta, gs and kitamura, s and ariyama, t 2007 recent advances in blast furnace modeling in india. Iron is made by reacting iron ore iron oxide and impurities, coke a reductant and limestone caco 3 in a blast furnace.
The iron produced in this way always contains high levels of impurities making it very brittle. 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. In a blast furnace, fuel coke, ores, and flux limestone are continuously supplied through. The liquid pig iron tapped from the blast furnace is saturated in c, with typical contents of 3.
Process analysis for blast furnaces by the discrete. The furnace is heated constantly and is recharged with raw materials from the top while it is being tapped from the bottom. In a blast furnace, fuel coke, ores, and flux limestone are continuously supplied through the top of the furnace, while a hot blast of air sometimes with oxygen enrichment is blown into the lower section of the furnace through a series of pipes called tuyeres, so that the chemical reactions take place throughout. Remaking the global steel industry lowercost natural gas. The basic oxygen furnace bof is a refractorylined, tiltable converter into which a vertically movable, watercooled lance is inserted to blow oxygen through nozzles at. It boasts strong technological force in engineering design for construction andor modernization of blast furnaces, hot stoves, pci systems, slag granulation systems, etc. Not all steel plants produce all of the products shown in this diagram. The ore part of a charge consists of iron ores and concentrates, manganese ores and various types of scrap containing iron. Blast furnacing, smelting and direct iron reduction are the current. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally iron, but also others such as lead or copper. In this method, steel is produced directly from iron ore. The term carburisation also spelled carburization covers a variety of ancient and modern processes in which iron at a high temperature but in the solid state takes up carbon from an environment rich in carbon or carbon monoxide. Process monitoring of ironmaking process in a blast furnace.
The rest has been produced by dri approximately 8 percent. Unlike the slag of other steel making processes electric arc furnace, basic. The basic oxygen steelmaking process differs from the eaf is that bof is selfsufficient in energy. 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. Now there are nearly 700 blast furnace available in world. This is done by oxidising the elements concerned by blowing pure oxygen through a lance. The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. These blast furnace and coke making co2 emissions made.
Blast furnace products and there use size of blast furnace design of blast furnace is evolved through experience. Us steel operates a number of integrated steel mills, including the gary works in gary, indiana. Moving on to steelmaking processes, the first thing is to mention that there are two basic ways of making steel. The process is on a cyclone converter furnace a new type of blast furnace. Ferrous comes from, or contains iron, while nonferrous does not contain iron. Process involved in manufacturing carbonization of coke blast furnace basic oxygen steel making bos electric arc method 3. 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. Processes such as coke oven heating, continuous casting, furnace reheating, hot rolling. Valia, scientist, ispat inland inc introduction a world class blast furnace operation demands the highest quality of raw materials, operation, and operators.
Calculation of blast furnace size is empirical in nature. We will briefly trace the evolution of coal and oil formation and discuss the links between coals and kerogen macerals through. When comparing carbon efficiency of hot metal in a blast furnace. Pig iron production blast furnace route more than 1. Coke is the most important raw material for the blast furnace in terms of operation and hot. The principle of blast furnace operational technology and.
Cisdi supplied the largest number of blast furnaces over 4,000m 3, and is the company which has the experience of epc of blast furnaces. Hot metal from the blast furnace is added by pouring from a ladle through a trough positioned in the door. Scrap is charged to the furnace through doors in the furnace front. 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. The process of stopping the blast furnace operation at the end of its campaign is known as.
The german steel federation wv stahl in order to make steel, iron must be extracted or won from iron ore. The main objective of blast furnace ironmaking is to produce hot metal with consistent quality for the bos steelmaking process. Pdf the nodal wear model nwm is used to explain and quantify the causes for. Constructal design of a blast furnace ironmaking process. The mixture of scrap and hot metal can vary from all scrap to all hot metal, but a halfandhalf mixture is most common. Energy required of key processes in iron and steel industry. Today there are two major commercial processes for making steel, namely basic oxygen steelmaking, which has liquid pigiron from the blast furnace and scrap steel as the main feed materials, and electric arc furnace eaf steelmaking, which uses scrap steel or direct reduced iron dri as the main feed materials.
More than half the worlds steel is produced in the basic oxygen process bop, which uses pure oxygen to convert a charge of liquid blast furnace iron and scrap into steel. The no 6 blast furnace produces around 7,300 tonnes of molten iron per day. Blast refers to the combustion air being forced or supplied above atmospheric pressure. A blast furnace is a reactor which produces an impure form of molten iron, termed hot. The blast furnace iron making process bfimp is the key of the integrated steel enterprise for energy saving due to its largest energy consumption proportion. Steel production basics steel is produced using primary or secondary methods, as shown in figure 2. A simplistic overview of the steelmaking process from iron ore to car body. 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. The manufacture of steel royal institute of chemistry. 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 cokemaking process involves carbonization of coal to high temperatures 1100c in.
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