Report on annual worldwide carbon dioxide emissions from blast furnace iron ore smelting and cokemaking abstract the 2015 worldwide co2 emissions from blast furnace iron smelting, and associated cokemaking and ancillary activities came to 2. Blast furnace smelting equipment sinter plant lime kiln. Various term used to describe a blast furnace and its equipment are described below. Blast furnaces, steel industry and trade publisher osceola mills, pa. Aug 07, 2015 steel manufacturing process infrastructure coke ovens and coal chemical plant sinter plant blast furnace steel melt shop and continuous casting lmmm wrm mmsm 10. The blast furnace process can be briefly described as follows. Sri 2001two products are obtained from the bottom of the blast furnace.
Iron oxides, flux agents, and metallurgical coke are added to a skip car at the stock house. After cleaning, it is used for a variety of purposes, including heating of the hot blast. The formation of iron and steel the blast furnace 2. Coke is the most important raw material fed into the blast furnace in terms of its effect on blast furnace operation and hot metal quality.
Arcelormittal poland is planning to temporarily idle the operation of the blast furnace and steel plant at its krakow unit. Fritz w lurman, a well known blast furnace man of the time opined in 1892 that irrespective of the use of so called refractory materials, the best means of maintaining the walls of the blast furnace is with cooling water. Typical sinter suitable for blast furnace process is from 15 to 25 mm, as is illustrated in figure 1. The corex process combines coking plant, sinter plant and blast furnace into a single iron making unit. 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. Robust descriptions of the main equipment and systems, process technologies, and best practices used in. They typically contribute to more than 60% of a steel plants energy requirements and are used either as a direct fuel substitute or for the internal generation of electricity.
Ironmaking blast furnaces consist of several zones. Coproduct gases from the coke oven, blast furnace bf and basic oxygen furnace bof are used, saving on additional fossil fuel and energy resources. With design, manufacture and installation of pig iron, ferromanganese smelting blast furnace, sinter plant, hot air stove, cip system, shaft furnace, lime kiln, etc. 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. The primary source of blast furnace emissions is the casting operation properties and uses of iron and steel slags d. 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. Blast furnace plays a vital role in an integrated steel plant for producing pig iron which is then converted into various grades of steel in an arc furnace 6.
This can perhaps be explained by the vast amount of blast furnace slag available 6. The energy in blast furnace gas in the forms of pressure and temperature is recovered by a trt generator after passing through the dust collector. Plant and equipment, metallurgical processes, chemistry, raw materials, products and byproducts, operation, alternative. Blast furnace smelting equipment sinter plant lime. A world class blast furnace operation demands the highest quality of raw materials, operation, and operators. Listed below are the highlights of the blast furnace at vsl steels. Where co 2 is released when using coal, hydrogen simply produces steam. Preceded by a detailed market analysis which confirms weakening demand, the decision is an unavoidable outcome of rising prices of co 2 emission allowances and high imports from countries outside the european union, as. These blast furnace and cokemaking co2 emissions made up 5. A dryprocess dust collector for blast furnace is equipment for cleansing blast furnace gas. Steel duquesne works, blast furnace plant, along monongahela river, duquesne, allegheny county, pa enlarge view 81 images in sequence. Access tower this tower is made of steel with platforms at various levels so that easy access can be made to various levels of the furnace. 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. Bw pdf download a blast furnace is a type of metallurgical furnace used for.
This guideline of safety is applicable to blast furnace dept. Blast furnace gas blast furnace gas is a byproduct of blast furnaces where iron ore is reduced with coke into metallic pig iron. A high quality coke should be able to support a smooth descent of the blast furnace burden with. When the flux is added at the sinter plant, the limestone is. The blast furnace process has auxiliary equipment associated with it. Water requirements of the iron and steel industries by faulkner b. Conversion of coal into coke it can be achieved by using coke ovens and coal chemical plant heating the blended coal charge in absence of air at a temperature of oc1050oc for a. Soon well be using hydrogen as a reducing agent in the blast furnace instead of carbon, says dr. The blast furnace ironmaking process had, until recently, been the unchallenged method of making hot metal on a large scale. Overview of the steelmaking process pellets sinter limestone coke iron ore coal scrap blast furnace ironmaking converter steelmaking ladle refining blast furnace steelmaking coalnatural gas plate hotrolled bars rods tube rounds rails slab billet bloom. Aug 04, 2011 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.
While blast furnace slag has a long history of use as an industrial byproduct, going back almost 100 years in the united states and 150 years in europe 8, steel slag was less popular. Blast furnace slag bfs which is defined as the nonmetallic product consisting essentially of silicates and alumina silicates of calcium and other bases, that is developed in a molten condition simultaneously with iron in a blast furnace by astm c 12516 2016 has been widely used in construction industry for more than 80 years. Step 2a the blast furnace the sinter is added through a hopper at the top of the blast furnace. Alumina refractories these refractories are used for lining of blast furnace. The blast furnace byproduct gas, which is collected from the furnace top, contains co and particulate. 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.
This auxiliary equipment and the gaseous pathways inside a blast furnace process are shown in fig. Robust descriptions of the main equipment and systems, process technologies, and best practices used in a modern blast furnace plant are detailed. Since then many other alternative processes of iron making have arisen e. Pdf recycling of blast furnace sludge within the integrated. Topics blast furnaces, steel industry and trade publisher osceola mills, pa. Till 1990, the blast furnace route of ironmaking had about 97% 527mt share of global iron production. However, this statement can be considered only partially correct. The raw materials require 6 to 8 hours to descend to the bottom of the furnace where they. Steel manufacturing process infrastructure coke ovens and coal chemical plant sinter plant blast furnace steel melt shop and continuous casting lmmm wrm mmsm 10. Steelmaking is the process of producing steel from iron ore andor scrap. The blast furnace gas that leaves the top of the furnace is a mixture of carbon dioxide, carbon monoxide, hydrogen and nitrogen and has a calorific value between 3,200 and 4,000 kjm after cleaning, it is used for a variety of purposes, including heating of the hot blast stoves cowpers, in iron ore agglomeration plants and for. 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.
Steel plant museum of western new york 705,643 views. Important properties of sinter for blast furnace process are reducibility, size and size distribution, cold and hot strength, and softening and melting behavior. In a blast furnace, fuel coke, ores, and flux limestone are continuously supplied through. Because of its high co content, this blast furnace gas has a low heating value, about 2790 to 3350 joules per liter jl 75 to 90 british thermal units per cubic foot btuft3 and is used as a fuel within the steel plant. The iron ore concentrate is now mixed and ready for the pelletizing process. Health and safety executive contents introduction 3 executive summary 3 the event 3 the cause 3 the investigation 4 lessons 4 background 8 the company 8 the plant 8 the management structure 8 the blast furnace 9 the structure of the blast furnace 9 the ironmaking process 11 no. Steel homestead works, blast furnace plant, along monongahela river, homestead, allegheny county, pa enlarge view 57 images in sequence. Potential for complete recycling and influence on operation thesis pdf available october 2019 with 36 reads how we measure. Because of its high co content, this blast furnace gas has a low heating value, about 2790 to 3350 joules per liter jl 75 to 90 british thermal units per cubic foot btuft3 and is used as a. Recycling of blast furnace sludge within the integrated steel plant. Secondary steelmaking involves refining of the crude steel before casting and the various operations are normally carried out in ladles. Primary steelmaking involves converting liquid iron from a blast furnace and steel scrap into steel via basic oxygen steelmaking, or melting scrap steel or direct reduced iron dri in an electric arc furnace. Arcelormittal poland is planning to temporarily idle the.
Another important property is the disintegration of sinter in reduction, which occurs during the transformation of hematite. Harbisonwalker refractories acero alloy appointed basic oxygen basic oxygen furnace blast furnace carbon carrier. Report on annual worldwide carbon dioxide emissions from. The blast furnace module is part of the steel manufacturing course. The metallic iron produced by such a furnace contains a relatively high proportion of. Raw materials like iron ore, coke, limestone are charged at the top of the blast furnace through skip car system. 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. This module introduces the learner to the operation of the blast furnace for the transformation of iron ore to molten iron.
The energy in the furnace gas has been lost in the conventional wetprocess dust collector as the. Blast furnace slag in the production of hot metal, the blast furnace is charged with ironbearing materials iron ore, sinter, pellets, 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. Arnd kofler, chief technology officer at thyssenkrupp steel, explaining the first step toward avoiding co 2 emissions. Blast furnaces may have the following ancillary facilities. Blast furnace process an overview sciencedirect topics. Steel duquesne works, blast furnace plant, along monongahela river, duquesne, allegheny county, pa photos. Analysis, control, and optimization uses a fundamental first principles approach to prepare a blast furnace mass and energy balance in excel.
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. Steel corporations canadian metchem consultants, limited neeland, marvin a westinghouse electric company wilsonsnyder usx corporation american air filter company keystone. This code of safety is applicable to blast furnace dept. 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. Harbisonwalker refractories acero alloy appointed basic oxygen basic oxygen furnace blast furnace carbon carrier corp cent chemical coal coke oven construction div continuous casting crane davis fire brick engineering and construction engineering or foundry facilities foundrymill machinery div. Our facility consists of a blast furnace that is of 262 m3 capacity and is used for producing pig iron.
Process 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, coke, fluxes limestone quartzite. Blast furnace, coke gas and converter gas for power production. Pig iron blast furnace route international iron metallics. Integrated iron and steel mills produce steel by reducing iron ore to iron in a blast furnace and, subsequently, removing excess carbon and other impurities from the iron in a basic oxygen furnace. Not all steel plants produce all of the products shown in this diagram. Glossary of terms used for a blast furnace ispatguru. Blast furnace 5 life extension project tim rutter steps inside the furnace. 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. As the worldwide first of several tests, hydrogen has been injected. 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. Fagioli blast furnace replacement fos sur mer duration. Captive power plant runs on generated blast furnace gas which is otherwise was being flared to atmosphere. Blast refers to the combustion air being forced or supplied above atmospheric pressure.
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