A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals. For new turnkey installations of any capacity as well as for plant rebuilds, the modern blast furnace designs produced by paul wurth are based on the concept of a freestanding unit with a surrounding building structure, providing access to the furnace and support for the furnace offgas system. Blast furnace, cooling and bricks researchgate, the professional network for. The challenge set by the greenhouse gas emissions of the blast furnace is being addressed in an ongoing european program called.
A new blast furnace shell means the use of the standard. The downward flow of the ore along with the flux in contact with an upflow of hot, carbon. Blast furnaces are similar to furnaces, but can smelt only ore blocks and toolsarmor made of iron, gold or chainmail. The software contains the following parts operating systems rsx 11m and s general purpose data acquisition and process data handling software by outokumpu, blast furnace specific software utilizing the real time data base by ovako operational results development of the online process supervislon system has contributed to reducing the. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. The carbon is fed to the blast furnace in the form of coke pyrolyzed coal from the coking plant. Power factor improvement equipment m m r y b m preliminary oltc it shall be suitable for 100% bidirrectional power flow sync provision shall be kept at 11 kv bus m. Europes biggest blast furnace a colossus being made fit for the future. Learn more who are renowned for creating steel using a blast furnace process and very short step from the blast furnace. Sep 28, 2019 the theory aim is allowing a critical view to be taken to the steps in a process or system information regarding bodily elements or structure has been abandoned to schematic diagrams or blueprints. If you scroll past the diagram you can read about the blast furnace process.
Process flow diagram agile software development flowchart. The principal raw materials used in the blast furnace operation consist of. A blast furnace works by blasting hot air up through the furnace while fuels, limestone, and ore move continuously through the top of the furnace. The blast furnace process can be briefly described as follows. M m blast furnace 3036 mva 11kv220kv, dyn11 power transformer.
The method used in blast furnaces have been used since the 1500s. A blast furnace is usually built with a steel case and bricks made of magnesium oxide or other refractory material inside the case. 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 principle of blast furnace operational technology and. Blast furnace is a large furnace which is used in metallurgical field to produce metals, especially pig iron. The iron in the processed ores must be dissolved out by chemical processes. In this simulation you will play the role of plant metallurgist in charge of the blast furnace operations. Blast furnace design ironmaking our activities site. The iron ore concentrate is now mixed and ready for the pelletizing process. A schematic overview of the blast furnace process is illustrated in figure 1. Blast furnace operation an overview sciencedirect topics. Process flow diagram pfd is a commonly used chart in chemical engineering and process engineering demonstrating the ongoing production flow of chemicals and other types of equipment involved. 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. The blast furnace is a large steel structure about 30 metres high.
Blast furnaces are used to produce pig iron from iron ore for subsequent. Numerical analysis on flow behavior of molten iron and slag in main trough of. Software for decisionmaking support in blastfurnace operation. At sufficiently high temperatures, the carbon can participate directly in the. A suitable slag composition was found to satisfy the smelting process in a blast furnace with superhigh tio 2 content at low temperature by using more mgo and less cao content. Page iii certificate this is to certify that the thesis entitled, study of blast furnace stave cooler based on heat transfer analysis submitted by prashant kumar azad in partial fulfillment of the. In the iron and steel industry, it is crucial to improve the quality of not only products but also manufacturing and operation technologies, as well as to address environmental and energyefficiency issues. The furnace is cooled with water running inside part of the case and bricks. Two large blast furnaces that began their operation in. Dec 26, 2019 it may have potential for application in the blast furnace ironmaking process with superhigh 80 pct vanadium titanomagnetite. The formation of iron and steel the blast furnace 2. 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. Tasks for which software is developed are described.
It is lined with refractory firebricks that can withstand temperatures approaching 2000 o c. As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. Blast furnace is a vertical shaft with circular cross section. 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. Oct 29, 2014 europes biggest blast furnace a colossus being made fit for the future. Blast furnace ironmaking process with superhigh tio 2 in the.
The blast furnace operates as a countercurrent exchange process whereas a bloomery does. 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. Blast air for the combustion process enters the blast furnace through tuyeres. 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. The furnace gets its name from the method that is used to heat it. Sintering or pelletising improves the blast furnace operation and reduces energy consumption. 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. Vector symbols help develop accurate and presentationquality diagrams and documentations. But our study is confined to the extraction of iron from its ore. This requires an element that binds oxygen more strongly than iron. Application of the developed system allows the engineering and process staff to analyze online production situations in the blast furnace plant, to solve a number of process tasks related to.
Characteristics of the main subsystems of the blast furnace process as an object of modeling and control thermal. Ironmaking 101 from ore to iron with blast furnaces. A typical blast furnace may be up to 32 metres in height and 10 metres in diameter. The concept of the process flow diagram was first pointed out by frank gilbreth, an american industrial engineer.
Secondary lead smelter etool smelting blast furnace. Block diagram of a computer decision support system. The tuyeres occasionally begin to fill with accretions and must be physically punched, usually with a steel rod, to keep them unobstructed. Reduction of roasted ore in the blast furnace smelting a major and primary lead mineral is galena chemical formula pbs which comprises of of lead in order to smelt this mineral, a blast furnace is needed to be used. Furnace parts diagram general diagram articles green eggs. In order to operate a blast furnace stably and economically, it is important to form an inversev shaped, cohesive zone in the high ore coke cohesive zone central gas improvement of liquid permeability in deadman formation of cohesive zone as inverse v shape deadman deadman.
Iron oxides, flux agents, and metallurgical coke are added to a skip car at the stock house. 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. The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. Blast furnace simple english wikipedia, the free encyclopedia. This is exactly what carbon can do as a reducing agent. Iron is made by reacting iron ore iron oxide and impurities, coke a reductant and limestone caco 3 in a blast furnace iron ores with lower iron content such as taconite are first processed to concentrate the iron level and drive off volatile impurities. Blasts furnaces are used for smelting during the production of metals such as iron, lead, zinc, and copper. Jul 15, 2014 fig 1 typical schematic diagram of a submerged arc furnace for ferro chrome production along with material balance. Process depiction by means of the rist operating diagram. Aug 18, 2016 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.
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. Fuel is also used at double the rate of regular furnaces. On the diagram below of the blast furnace, just click on the labels for a more detailed description. The paper presents the results of an investigation to determine the properties of aircooled blast furnace slag relevant to the use of the material in a road pavement base course. A blast furnace is usually built with a steel case and bricks made of magnesia inside the case. 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. In a blast furnace, iron ore reacts with hot coke to produce pig iron. Pdf information modeling system for blast furnace control. Blast furnaces differ from bloomeries and reverberatory furnaces in that in a blast furnace, flue gas is in direct contact with the ore and iron, allowing carbon monoxide to diffuse into the ore and reduce the iron oxide to elemental iron mixed with carbon. This auxiliary equipment and the gaseous pathways inside a blast furnace process are shown in figure 2.
Blast furnace iron making is the main method for modern steel production,the process of blast furnace is an important part. Figure 2 a shows a schematic diagram of blast furnace interior. The removal of oxygen through the chemical process called reduction is crucial oxygen combines with carbon monoxide, forming carbon dioxide gas. This is to certify that the thesis entitled, study of blast furnace stave cooler based on heat transfer analysis submitted by prashant kumar azad in partial fulfillment of the requirement for the award of the degree of master of technology degree in mechanical engineering with specialization in thermal engineering at. The blast furnace process has auxiliary equipment associated with it. Lead or copper can also be produced in the blast furnace. A variety of processes take place within the blast furnace, as the stock slowly moves downwards and temperatures increase. Development of a blast furnace model with thermodynamic. The steel maker controls the sintering process to produce a consistent iron quality. Evaluation of energy and co2 emission strategies in blast furnace.
Study of blast furnace stave cooler based on heat transfer. Predrawn boiler symbols represent boiler, boiler with flames, hot blast heater, blast furnace, firebox boiler, heating furnace, skidmounted boiler, steam boiler, etc. 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. Preheated air at about o c is blasted into the furnace through nozzles near its. They have thick steel sides, lined with refractory bricks, to ensure that heat is not lost. The research program of the competence center k1met is supported by comet competence center. Blast furnaces are used to produce pig iron from iron ore for subsequent processing into steel. Your aim is to optimise production of hot metal from your blast furnace by selecting appropriate raw materials, production statistics and charging rates. This is to certify that the work in this project report entitled cfd modelling of heat transfer in blast furnace by biswajit dalai 111mm0268. The blast furnace process coke and ore burden distribution coke ore burden 0 4 51 2 3 0. History the increasing demand for ferro alloys and deoxidation agents in steel making in the beginning of the twentieth century led to the development of the first submerged arc furnace. The burden charge consisting of iron oxide, flux and coke and it provides through the throat from the top of the furnace. It is the distribution of gas flow within the furnace which largely determines the.
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