Académique Documents
Professionnel Documents
Culture Documents
SEPARATION OF PIG
IRON AND SLAG
Ruchita Deulkar
(13118075)
Condition
The slag must have the affinity for absorbing impurities i.e. gangue from
charge along with other deleterious impurities which affect the quality of
hot metal
1) Reduction in the activity of other metal oxide .
2) Lowering the M.P. of unwanted materials .
3) Solubility :- Two phases value and slag should be immiscible into each
other.
4) Sufficient difference in the specific gravities of the two phases like slag and
metal.
5) Slag should have no solubility for metal value.
6) Slag should have sufficient fluidity
7) The melting point of the slag is to be neither too high nor too low
8) The final slag is to be fluid enough so that it is possible to drain it through
tap hole
As temperature increases viscosity decreases so fluidity increases , this shows
that temperature in blast furnace for separation process of pig iron and slag
can not be only decided by melting point of slag but also by fluidity of slag.
Md Tanveer Alam (13118043)
PIG IRON
It is the molten iron extracted from iron ore by Blast Furnace.
During the process of smelting, the liquid iron absorbs and combines with a considerable
quantity of carbon, sulphur, silicon, phosphorus, and manganese from the ore and coke.
Some of the carbon is chemically combined with the iron in the form of iron carbide, while
the remainder exists as a form of free carbon called graphite.
Compositions
Iron (Fe) 93.1 - 95.4%
Carbon (C) 3.5 - 4.5%
Manganese (Mn) 0.4 - 1.0%
Silicon (Si) 0.5 - 1.2%
Phosphorus (P) 0.15%
Sulfur (S) 0.04%
Silica and other constituents of dross(Mn ,P ,S ,etc), which makes Pig Iron very brittle and
not useful directly as a material except for limited applications.
SLAG slag is the by-product left over after a hot metal has been separated from iron ore.
Slag is usually a mixture of metal oxides and silicon dioxide.
SLAG PROPERTIES
GLOBAL
32 to 45
5 to 15
32 to 42
7 to 16
1 to 2
0.1 to 1.5
0.2 to 1.0
0 to1
INDIAN
30 to 35
2 to 4
29 to 36
24 to 29
0.8 to 1.2
0.5 to 2.5
0.5 to 1.3
0 to1
The slag should be fluid (viscosity) so that it can be removed easily during tapping.
This ratio should be 1.1-1.2 for best slagging.
Basicity Its density is lower than that of the hot metal, so we can easily separate it.
It has good permeability (in slag formation zone) and also has appropiate melting temperature
(neither too high nor too low), Low surface tension, High diffusivity.
High internal friction values and particle interlocking properties, which gives it a higher
strength.
NITIN PATEL (13118050)
Low surface tension, High diffusivity, Oxidation potential.
SLAG APPLICATIONS
Air-cooled slag
Granulated slag
Blast Furnace
The calculations are based on individual mass balance of different elements involved in the Blast
furnace process wherein the total elemental input from all sources is equated with total
corresponding elemental output ( product + waste ) as shown in example on next slide.
Ritvik Vipra, MMED
13118106
Kotipalli Mahitha , MMED
13118036
Mass Balances:
Amount of ore
Fe- Balance:
Feore = Fehot metal
(85/100)*(112/160)* x = 1000*(95/100)
x = 1596.64 Kg = Amount of Ore required
Carbon Balance:
Ccoke + Cflux = CB.F gas + Chot-metal
0.85*800=0.95*299.37*(12/100)=CB.Fgas+0.0036*
1000
CB.F gas= 678.12 kg = 56.51 Kmoles
CO molar fraction = 28/(12+28) = 0.7
CO2 molar fraction = 12/(12+28) = 0.3
Amount of CO and CO2 present is 39.56 and 16.94
moles respectively.
Amount of flux
Amount of slag
Ca Balance:
(95/100)*(40/100)* z = y *(40/100)*(40/56)
z = 0.75 y
Al2O3 Balance:
(5/100)* x = (20/100)* y
y = 399.16 Kg = Amount of Slag
Produced
By substituting y value z can be found,
z = 299.37 K = Amount of Flux to be added
Total B.F Top Gas = 90.32+39.56+16.94 = 146.82 Kmol = 146.82 * 22.4 Nm3 =
3289 Nm3
Ritvik Vipra, MMED
Volume of B.F Top gas = 3289 Nm3
13118106
Kotipalli Mahitha , MMED
13118036
Pressure profile of Blast Furnace is Mainly dependent on hot blast intake velocity and amount, top
gas exit velocity and amount, amount of CO and CO2 produced in different Zones of the Blast
Furnace, the amount of CO and CO2 consumed in the reduction reactions and Boudouard Reaction
respectively and the amount of moisture levels near tuyeres that produce water gas.
Chemical Kinetics and Thermodynamics of the above processes are studied to know the Gaseous
production rates and temperatures at different Zones that govern the Pressures in different zones of
Blast Furnace.
Several mathematical models have been
developed to find the pressure profile of the
Blast Furnace. This method can be verified and
modified accordingly, further the relevance of
equations available for estimation can be
improved with experience.
Method using the analogy of gas flow to
electrical conductivity with the use of
electrically conductive paper. This method is
Time consuming but can be useful for the
zones where Mathematical Equations are
unavailable for assumptions.
The pressure profile given here is developed
using several Mathematical models and
appropriate assumptions. It is showing
minimum possible errors.
Deadman Zone
Deadman zone(coke) is the packed coke bed with dense skin structure in
the lower zone of blast furnace occupying a region extending from the
hearth up to the tuyers and a roughly conical region above the tuyers up
into the bosh
Depending on the force and pressure distribution along the lower zone of
blast furnace as well as the angle of repose for the coke bed which is
exposed towards the preheated air(with PCI,natural gas) formation of
conical shaped almost stagnant zone,deadman zone(containing pile of
coke) takes place.
Deadman coke may float or sit in the hearth depending on the force
balance between buoyancy of the coke and weight of burden actually
applied on the deadman
Madhur Gupta(13118038)
Abhishek Grover(13118003)
By Divyansh Gothwal
There is an ongoing effort to reduce pig iron production cost which requires furnace productivity improvement, coke
and fuel rate reductions and longer furnace campaign life often while dealing with poorer raw material quality. To
meet the objectives and the limitations, the blast furnace process has to be transparent and it has to be modelled
accurately.
Rishabh Thakur
Blast furnace is a counter current reactor in which the burden descends as the hot blast gasifies the
coke at the tuyeres producing carbon-monoxide which flows upwards heating and reducing the
burden materials. This gas is distributed through the coke layers in the cohesive zone and into the
granular coke and ore layers. When the burden is charged into the blast furnace, it pushes the coarse
coke particles on the top of the coke layer towards the centre . This effect is called the coke push.
The optimized gas flow in a modern furnace operated at high productivity and low coke rate has the
inverted V shaped melting zone .However the gas escaping through the ore-free centre leaves the
furnace with low utilization . This loss of unused gas should be minimised . If the central gas flow is
too high, there is a too small gas flow along the wall for heating ,reduction and melting of the ore
burden and consequently the root of the melting zone comes close to the tuyeres . In this process the
reductant rate will be high and there is high chance of tuyere damage.
Therefore it is essential that the gas flowing through the centre distributes itself through the burden
layers. Therefore the permeability of the centre coke column must not be too high , which means that
the diameter of the central coke column must not be too wide.
If the central gas flow is blocked (partially),a relatively large part of the gas escapes along the wall and
is cooled down. The result is the part of the gas is cooled down low in the furnace and the reduction
reactions slow down. In this situation, the central gas flow is small and heat losses are high . Gas flow
control is based on keeping the balance between central and wall gas flow to the optimum.
Rishabh Parihar
Slag runners
runner
Skimmer
plate
TLC
At present Bhilai Steel Plant has 7 blast furnaces and 8th is under construction.
BLAST FURNACE No->
DIMENSION
1,2,3
4,5,6
Charging Materials
Iron ore Lumps
1033 m3
Working Volume
(Tuyere to stock
level)
886 m3
Full Height , mm
28750
31250
32350
14
18
24
Mn Ore
No of Tuyeres
1719 m3
2355 m3
Sinter
(Fe~50% Size:5-40mm)
Coke
1491 m3
(C:75-80% Ash:15-16%)
2105 m3
Limestone
(CaO~38%+MgO+SiO2)
LD Slag
+
(Mn:30%min Size:25-80mm)
Installation of a new furnace (BF-8) of capacity 8,030 t/d hot metal production (about 4060
m3 useful volume) at a separate location along with a new stock house and new material
handling facilities.
BSP's hot metal production is going to reach 7.5 MT per annum by its installation.
Quartzite
(SiO2 ~96% Size:25-30mm
+ Al2O3)
+
CDI Coal
steel annually. It also specializes in production of other products such as wire rods
and merchant products.
The main Products of blast furnace are liquid hot metal and the liquid slag which is
obtained by dumping iron ore, coke and limestone from the top and preheated air
blown into the bottom.
Hot Metal : 4.080MT/year
Slag volume:
Saleable Pig Iron: 0.63MT/year
Avg.: 620.00 kg/THM
Total Hot Metal Capacity : 4.71 MT / year Range: 521 704 kg/THM
COKE CONSUMPTION:
Coke consumption is amount(in Kgs) of coke consumed per tonne of hot metal in the
Blast Furnace (kg/THM). Coke consumption rate is 450 460 Kg/THM which is
reduced by achieving maximum CDI rate. Without CDI, coke consumption is 550-650
kg/THM.
Major facilities:3 sintering machines ,7 blast furnaces, coke oven,use of CDI and
coal tar ,pellets plant,2 slag granulation plant,2 steel melting shops ,refractory,2
material plant and different mills etc.
Production Capacity: 12.5 MTPA steel and 2500 MW of power(Angul).The pellet plant
at Barbil has a total capacity of 9 MTPA. The iron ore mine at Tensa produces 3.11
MTPA sponge grade iron ore.
Coal gasification plant to produce 225,000 nm3/hr of syn gas.
Technology : DRI-BF-EAF route would be adopted for steel production.
Has a unique feature of using syn gas from the coal gasification plants as reductant.
Used for first time in the world and has the advantage of using high ash coal.
Major Facilities include : Coal washery, Sinter plant, Pellet plant, coke oven and byproduct plant, coal gasification plant, DRI plant ,BF, Steel Melting Shop, Power plant.
Pallavi Jha 13118052
Presented by:
Brajesh kumar
Harish Parihar
Pulkit Khandelwal
Shubhankar Rajpoot
Shreya
Ankit Kumar
Anuj Agarwal
No coking properties.
Mainly used as thermal coal for
power generation.
Has a higher ash content.
Used in industries like
cement, fertilizer, glass, ceramic, p
aper, chemical and brick
manufacturing.
Indian Non Coking Coal is
classified on the
basis of Gross Calorific Value
(GCV) which
consists of 17 GCV bands.
Brajesh Kumar
Pulkit
- Saturated raw gas coming from the coke oven battery contains
around 46 % to 48 % water vapour.
- Raw coke oven gas also contains various contaminants, which give
coke oven gas its unique characteristics. These consist of
1.
Tar components
2.
Tar acid gases (phenolic gases)
3.
Tar base gases (pyridine bases)
4.
Benzene, toluene and xylene (BTX), light oil and other
aromatics
5.
Naphthalene
6.
Ammonia gas
7.
Hydrogen sulfide gas
8.
Hydrogen cyanide gas
9.
Ammonium chloride
10.
Carbon di sulphide
Shubhankar
25%
Ash
52%
Volatile
Material
18%
Moisture
2%
Ash
52%
C
31%
S
O 8%
7%
H
2%
N
0.1%
shreya
After all the above processes , the coal obtained would have much
less ash content and also the percentage of carbon would increase.
shreya
Australian Coal
Australia is the world's second largest
coal exporter, as it exports roughly
73% of its coal production
Mostly high-quality bituminous
coal (black coal) is found
Australia can supply the full range of
metallurgical coals. These include
traditional products such as hard and
soft coking coals as well as lower
grade metallurgical coals such as
semi-soft coking and PCI coals.
Australian coals have good coking
properties and are generally low in
Sulphur (0.3 to 0.8 per cent) and
many are low in phosphorus.
Ankit Kumar
CALORIFIC VALUE
COKING
PROPERTIES
SULPHUR CONTENT
MOISTURE
CONTENT
VOLATILE CONTENT
Decreases
Anuj Agarwal
Furnaces
Group -12
Group members
Alisha Anil Manwar 13120012
Amandeep Singh 13118006
Anu Garg 13214004
Divyanshu Gupta 13118021
Ravi Raj 13118071
Satyendra Kumar Tiwari 13121021
Seth Riddheish Anilkumar 13118080
Shubham Jain, 13118089
.
Material is fed into kiln from kiln tail. Due to the slope and rotation of the cylinder, the material make a composite
motionit rolls in circumferential direction and at the same time moves in axial direction.
After sintering process, the material is calcined in cement clinker and discharged into cooler machine through kiln head
hood, prayed into the kiln from the kiln head, the fuel burns in the kiln, after exchanging with the material, the generated
waste is discharged from kiln tail. The burner in this design is excluding fuel
NOVEL APPROACH
Advantages:
1. The rotary kiln has the function of the heat exchanger. The rotary kiln has the homogenous
temperature field.
2 The installation of the excellent combustion apparatus can ensure the full combustion of the fuel,.
3. With the different needs of cement clinker minerals in the different stages, it can not only meet the
heat exchange and temperature requirements of different minerals in different stages, but also can meet
their requirements on time.
4. Because the rotary kiln has high temperature field and thermal field stagnation air time long,
biodegradable chemical, pharmaceutical, etc discharge of poisonous and harmful waste.
SHAFT FURNACE:
Structure and principle-It is a vertical refractory lined cylinder in which a fixed bed or descending column
of solids is maintained ,and through which an ascending stream of hot gas is forced .The shaft furnace
works on counter current principle where the iron ore feed material moves downward in the furnace by
gravity and gets reduced by the up flowing reducing gases.
Notable examples- pig iron blast furnace, phosphorous(from phosphate rock) furnace.
Types- Shaft furnaces can either be static or tilt able (tilting model, where the shaft is static is possible too).
Operation based on principle-Moderate velocities of the gaseous combustion products are characteristic of
shaft furnace. The bulk of the lumped materials(the charge) s not entrained by the ascending gas stream
and, in contrast to the fluidised bed furnace, maintains aerodynamic stability. The counter-current motion
of the charge (top to bottom) and of the gases forced through the charge(bottom to top) and the direct
contact between the charge and hot gases result in good heat exchange and generation of low
temperature exhaust gases.
Consequently, shaft furnaces are characterized by a high thermal efficiency and a relatively high output. So
such furnaces are widely used to smelt iron ores and in non-ferrous metallurgy of Ca,Ni etc.
Parts of Simplified Shaft furnace shown
alongside:
(1) charging device
(2)gas outlet
(3)Tuyere
(4)outside crucible
(5)slag notch
(6) matte hole
(7) inside crucible
-Seth Riddheish Anilkumar , 13118080
Longer
lifetime
than other
furnaces
Applicable for
different scrap
qualities
Optimized thermal
efficiency with
atleast 40% lower
energy consumption
than other furnace.
ADVANTAGES :
Production of DRI(Direct Reduced Iron). Carbon source can be coal, coke fines, charcoal,
or other carbon-bearing solid.
Work flexibility and high reliability. High temperature uniformity :Suitable for heat
treating large quantities of the same parts. Furnace atmosphere easy to control and High
superheating power .
Overpressure control . Economical and Safe operations : Low consumption of
technological mediums . Easy service and maintenance.
High quality parts : no scale and decarburization .High repeatability of processes : Fully
automated and quick loading and unloading of the load .Used for various treatment
processes such as case hardening and carburizing (low case depth), neutral hardening,
reheating, tempering, annealing etc.
EXAMPLES :
FASTMET : Coal-based iron oxide reduction process. Uses a rotary hearth furnace to
convert steel mill wastes and iron oxide fines to highly metallized DRI. Extremely energy
efficient.
FASTMELT : Uses a rotary hearth furnace but adds an electric iron melting furnace for
production of a high quality hot metal known as FASTIRON . Can convert poor quality iron
ores and non-coking coals into quality pig iron products.
FASTEEL : More environmentally friendly as merging of the hot metal producing benefits
of FASTMELT with the continuous scrap feeding and preheating of CONSTEEL to produce
high quality steel.
FASTOx : High quality steelmaking for areas without economic scrap supplies, or clients
with pre-existing BOF equipment . Can use locally available iron ore fines and non coking
coals, coke fines, or charcoal.
ITmk3 : Processing iron ore fines into almost pure pig iron nuggets in only ten minutes.
Supply pig iron grade nuggets directly to the EAF steelmaking industry.
Amandeep Singh 13118006 MT-1
Fluidized Bed
Essentially consists of a main column in which the iron ore coal
mixture is fluidized at high velocity and a return column in which
the entrained solids from the main column are collected via a
cyclone. Solids from the return column are re-circulated to the
bottom of the bed in the main column through a control valve.
Fast bed conditions prevail in the main column and the solids in
the return column constitute the slow bed. Solids are
continuously fed in at the top of the reactor and enter the slow
bed through the cyclone. During this descent, the solids get
preheated by the rising gases. Partial reduction of the higher
oxides of iron also takes place.
The fluidized bed reactor operates at 400- 450 C temp. and 46
atm pressure. High pressure is required to produce non sticky
and un-sintered iron powder and increase reaction rate.
Conversion of iron oxide 98%
Hydrogen utilization 5% thus necessating recirculation of exit
gas after drying.
Highly pyrophric iron product is treated with N2 at 81- - 870C
before storing
Applications in powder metallurgical and briquetting industries.
Typical dimensions of 50 tpa rector: 1.7m OD and 29m height.
Approx .051 - .056 ton of H2 and .25 ton of O2 reqd. to process
1.4 ton of high grade magnetite to arrive at 1 ton of iron
Reaction aspects:
Divyanshu Gupta
13118021
Fluidized Bed
Advantages of Fluidized Bed
RAVI RAJ
EN-13118071
Flue gas is a by-product of blast furnace that is generated when the iron
ore is reduced with coke to metallic iron. It has a very low heating value.
Composition:
CO2 :18-20%, CO :24-27%, H2 :3-5% and N2 :55-57%(approximately)
Temperature:
The temperature of flue gas as it leaves the furnace is 120-3700C.
This pressure is utilized to operate a generator (Top-gas-pressure Recovery Turbine - i.e.
TRT in short), which can generate electrical energy up to 35 kwh/t of pig iron without
burning any fuel.
Uses:
Preheated BF gas along with preheated air has been used successfully in coke-oven
heating, soaking pits, and reheating furnaces.
Flue gas is used for many applications in a steel plant and, in addition, is used
Made by:
frequently for heating coke ovens.
Babita Bala (13118014),
Shraddha Suman (13121025)
It is normally being used mixed with either coke oven gas or converter gas or both.
The mixed gas is used as a fuel in various furnace of the plant.
Flue gas without mixing and without preheat can be used in -
1.
2.
3.
4.
The thermal advantage of using flue gas in gas engines for blowing
and for power generation has to overcome the heavy investment and
maintenance expense required for such equipment.
5. Boilers for power generation
The modern boiler house utilizes high steam pressure and
temperature with efficient turbo-blowers and generators. This
has
sufficiently reduced the thermal advantage of gas engines and hence their use
has become difficult to get
justified.
6.Gas turbines for power generation.
Made by:
Babita Bala (13118014),
Shraddha Suman (13121025)
Because of the presence of substantial amount of CO in the BF flue gas, it has a considerable
amount of calorific value and thus is utilized in hot blast stoves (for preheating hot blast),
power plants and gas engines. However, for
efficient use, gas has to be cleaned of the dust
g
(consisting of fine burden particles).
Initially, separation methods using water (wet
methods) were implemented. At present, a
combination of dry and wet methods is being
used. The advantage The dust separated via
dry method can be again sent for sintering
and fed in the Blast Furnace.
DRY METHODS: Primarily use equipment called
Dust-Catchers.
Gravity Dust-Catcher: The flue gases are
allowed to interact with some ascending gases
so that the dust particles attain a terminal
velocity and get separated.
Schematic diagram of BF gas cleaning system
KN Sasidar(13118034)
Cyclone Dust-Catcher: The separation mechanism is based on the action of centrifugal forces on the dust particles. The
gas is introduced through two tangential inlets (into a kind of shaft) with a velocity to force the dust particles to the
wall and separate them from the gas stream.
WET METHODS
After primary separation in the dustcatcher, or cyclone, the blast furnace top gas is scrubbed with water in the annular
gap scrubber to obtain has a single tower construction comprises the pre-scrubber/cooler and the annular gap
scrubber stages, and is followed by a high-efficiency, external moisture separator. The characteristics of the annular gap
scrubber are: Multiple dust removal mechanisms, Minimum scrubbing water requirements and Superior top pressure
control. The principal separating mechanisms in an annular gap scrubber are: Inertial interception, Turbulent
(Brownian) diffusion and Flow line interception.
Inertial interception : characterised by the different inertial forces of the varying masses. When the dust-laden gas flows
around the collecting water droplet, the dust particles of larger mass do not follow the flow lines of the gas stream. These
particles, propelled by the inertia force, strike and penetrate the water droplet, and thus are removed from the gas stream.
Turbulent diffusion : highly effective in removing smaller dust particles from the gas stream. Small particles, particularly
those below about 0.3m in diameter,exhibit considerable Brownian movement and do not move uniformly along the gas
streamline. These particles diffuse from the gas stream to the surface of the water droplets and are collected. This collection
mechanism can only function in scrubbers that promote turbulent flow of a gas-liquid mixture, operate at low velocity and
provide sufficient retention time.
Flow-line interception : It only functions if the gas streamline passes within one particle radius of the collecting water
droplet. The dust particle travelling along this streamline will touch the water droplet and will be collected.
A cyclone followed by an annular gap scrubber offers High dust removal efficiency of 85% or higher and to a guaranteed value
of 5mg/Nm3, minimum water requirement as the annular gap scrubber operates with a low and constant water-to-gas
ratio, reduction the size of the water recycle system and thus minimising energy consumption, suit it up for installations for
low top pressure furnaces as well as for installations with top gas energy recovery turbines.
Made by Apurva
Gas Recycling
The concept of the Top Gas Recycling Blast Furnace relies on separation of the off gases so that
the useful components can be recycled back into the furnace and used as a reducing agent. This
would reduce the amount of coke needed in the furnace. In addition, the concept of injecting
Oxygen (O2) into the furnace instead of preheated air, removes unwanted Nitrogen(N2) from the
gas, facilitating Carbon dioxide(CO2) Capture and Storage (CCS).
CCS plays an important role in Gas Recycling:
A promising technology for significantly reducing the CO2 emissions from the blast furnace is to
recycle reducing gases (CO and H2) leaving the furnace with the top gas. The re-use of these
reducing gases lowers the usage of fossil carbon (coke). To reclaim them, however, the CO2
needs to be removed from the top gas, recycling the remaining gas back into the furnace. In
addition, to avoid build-up of N2 in the furnace, the blast furnace needs to be operated with pure
oxygen, instead of hot blast. For reaching a 50 % CO2 emissions reduction target, CCS
technology is necessary to store the captured CO2.
Prepared
by:
Vikram
Kumar
(13118105)
Gas Generation
In blast furnace, gas generated occurs as by-product when iron ore is reduced to molten iron
(Fe). The operation of the blast furnace is controlled to produce hot metal of a specified quality
and during this production BF gas comes out from the furnace top. Around 1500-1700 cu-m/ton
of hot metal of BF gas is generated during the process.
CO2 and CO generation:
When the hot air blast is blown in the furnace through
the tuyeres, Oxygen in the air reacts with coke to give
carbon dioxide
C(s) + O 2(g) CO2(g) H= -58230 J
then the limestone breaks down to form carbon dioxide
CaCO3(s) CO2 (g) + CaO(s) H= 41800 J
Carbon dioxide produced reacts with more coke to
produce carbon monoxide
CO2(g) + C(s) 2CO(g) H= 41500 J
The CO/CO2 ratio can vary in a blast furnace from
1.25:1 to 2.5:1. Higher percentage of CO in the gas
makes the BF gas hazardous.
HCN and CN2 generation:
In blast furnace some hydro cyanide (HCN) and Cyanogen gas (CN2) can also formed due to the
reaction of nitrogen in the hot air blast and carbon of the coke. The reaction is catalyzed by the
alkali oxides. These gases are highly poisonous.
Rohit(13118074) and Jasjot(13118033)
IMPURITIES IN ORE
Main impurities in iron ore are silica, phosphorous, sulphur, alumina
SILICA: Silica is the most common impurity. This is because of the
physical contrast between silica-rich minerals, like quartz, and iron-rich
minerals
PHOSPHOROUS: Phosphorous is one of the nasty impurities in iron ore. It
results in brittle iron. It is not easy to remove phosphorous so it is
preferable that ores are low in phosphorous to start
SULPHUR: Like phosphorous, sulphur is an impurity to avoid in iron ores.
High sulphur ores (>0.01-0.03%) are to be avoided as it ultimately
makes iron brittle, prone to cracking and failure.
Coke is a fuel and reducing agent in Blast Furnace with few impurities and
a high carbon content, usually made from coal.
It is the solid carbonaceous material derived from destructive
distillation of low-ash, low-sulphur bituminous coal.
Impurities present in coke are ash(inorganic residue after burning),
Sulphur, Phosphorous and other volatile matter.
Ash usually contains refractory oxides like SiO2,Al2O3,CaO,etc..
Phosphorous and Sulphur are also present in ash in the form of inorganic
compounds.
Coal available in India contains 2-7% of sulphur in it.
All the Phosphorous and some part of sulphur goes into the pig iron.
Sulphur in the coke requires additional flux for its removal or else sulphur
content of iron goes up.
Ash combines with the flux and is removed as slag.
Shaik Syed Akram
13118081
The most frequent impurities in limestone are dolomite ,silica ,alumina , clay minerals
, and the oxides and hydroxides of iron and manganese, as well as pyrite, phosphates,
and organic matter .
There are other trace elements that are present in limestone are sulphur ,
phosphorus, arsenic, manganese and fluorine.
Phosphorous gets completely into molten iron.
Molten Iron consists of 0.4-0.6 % Si , 0.1-0.2 % P , 0.040-0.050 % S , 0.1-0.5 % Mn.
Alumina ,Silica , MgO , 0.1-1.2% Mn and 1-2% S goes into Slag.
Other volatile materials are removed as gases.
Anugu Shashank
13121003
BASICS
Zinc Removal
ZnO from ore and coke gets reduced to Zn,
which cyclically vaporizes and condenses in
top parts of BF, thus builds up
Removal ensured by allocation in BF slag
and top gas (higher gas temp and higher gas
velocity, higher Zn content)
Controlling at sinter stage by adding NaCl or
CaCl2 during sintering which affect
evaporation of Zn
Phosphorus Removal
P2O5 gets completely reduced to
P. Therefore, virtually all of the
P in the burden materials will
dissolve in the hot metal.
Lakshman N. Chakrav
13120013
Sodium Removal
Na2O from ore gets partially reduced
to form Na vapor, builds up by
vaporization and condensation cycle
Vapor removed by maintaining central
gas flow, Na2O removal favored by
forming low-basicity slag
Sulphur Removal
S in form of FeS, gets reduced in
presence of CaO, in hearth (at very
high temp.)
Governing reacton:
FeS + CaO + C = Fe + CaS + CO2
Removal depends upon hearth temp,
slag basicity, slag volume
Agniva Si
13118005
FURNACE IRREGULARITIES
For a stable and efficient operation of a blast furnace, smooth and uniform movement of burden materials downward and movement of furnace gases in the
upward direction is very important. In spite of these improvements, the blast furnace does not run as smoothly as one is led to believe. Furnace upsets are not
as frequent as they were in earlier years but irregularities still do occur.
IRREGULARITIES
REMEDIES
Leaky Tuyeres
A leaky tuyere results usually from wear or from local superheating or " burning" of the metal,
whereby the cooling water is allowed to leak into the furnace hearth. If the leak is not promptly
discovered and stopped, it may result 'in serious cooling of the hearth
Furnace
Hanging
When the materials charged at the top of the blast furnace do not move continuously towards
the hearth of the furnace, the phenomenon is called hanging of the burden. Hanging of the
burden material in the blast furnace stack occurs when the material below the hang continues
to move downward, forming a space that is void of materials but filled with gas at very high
pressure.
Slipping
The collapsing of the hang is a phenomenon called slipping during which the charged materials
fall uncontrollably toward the hearth of the furnace in a thermally unprepared state which leads
to the furnace getting cold. The sudden rush of gases opens the furnace top gas bleeder and
sometimes can cause top equipment damage.
Channeling
The phenomenon of channelling happens when the ascending gases in the furnace does not
properly get uniformly distributed both radially and circumferentially in the furnace and find a
passage of least resistance. The different causes for channelling to occur in the blast furnace are
charging of excessive fines, improper distribution of the burden material inside the furnace.
Scaffolding
The term scaffolding is used when accretions or scabs build up on the furnace walls and cause a
decrease in the cross sectional area of the stack of the blast furnace. Scaffolding can occur
relatively at the higher level of the stack of the blast furnace or relatively low in the stack, near
the top of the bosh.
IRREGULARITIES
REMEDIES
Chilled
Hearth
Affects tapping adversely as tap holes are blocked. It may result because of low
fuel input, excessive moisture in the blast, water leaking from tuyeres, etc.
Slipping can also cause chilling.
Breakout
These are caused by failure of the bosh walls or hearth walls or hearth bottom
with the result that the liquid iron or slag or both flow out of the furnace in an
uncontrolled fashion.
Pillaring
Blast is unable to penetrate right up to the center of the furnace, this leads to
the formation of a cold central column of the stock with an annular hot zone
around it.
Choking of
Gas Offtake
Flooding
An increase in the gas or liquid flow can prevent the liquid metal and slag from
flowing downwards, causing it to accumulate in the coke interstices until the
weight of the liquid overcomes the upward thrust of the gases and descends
suddenly into hearth.
The interruption in uniform blowing rate causes the raceway to collapse and
when it is resumed again the small particles of coke can not re-enter the
raceway and consequently descend into the hearth, instead of burning in the
tuyeres region, resulting in a choked hearth.
Coke Ejection
In general, immediate detection and correction of any irregularity is essential to avoid serious troubles
and loss of output.
Mayank Jain
13118042
PHYSICO-CHEMICAL ASPECTS OF
BLAST FURNACE
(GROUP- 3)
TUYERE:
Coke is the only constituent of the
burden that descends down into the
tuyere zone in the form of a solid
column.
Pranav B. 13118057
Nitin kant 13118049
At
temperature
greater
than
570
BOSH:
FeO + CO
Fe + CO2.
The reduction of iron oxide by the CO
content of the ascending gases and directly Besides of reduction of iron oxide, higher
oxide reduce to lower oxide as,
by solid coke or carbon deposited by the
MnO2 + CO
MnO + CO2
Naumann Reversion continues and goes to
completion in the bosh region.
Mn3O4 + CO
MnO + CO2
Softening also occur while descending Further reduction of MnO to Mn is
through the bosh zone.
possible only by carbon at higher
temperature level.
Reactions in the bosh zone of blast furnace:
SiO2 + 2C
Si + 2CO
THROAT:
FeS + CaO + C
CaS + Fe + CO
The region where the burden surface
P2O5 + 5C
2P + 5CO
exists.
MnO + C
Mn +CO
In blast furnace, any fraction of the components is governed by thermodynamic equilibrium state in C-O-Fe system
and reaction kinetics caused by the difference between actual and equilibrium state. The Fe-C-O system can be
broken down into three steps.
1.Combustion (reducing gas generation):- In blast furnace, carbon atom of coke reacts with oxygen
molecule from tuyere.
C(s)+O(g) =CO2(g) H298 = -393.5 KJ/mol. Where H is the heat of formation of the reaction. Generated carbon
dioxide by above reaction reacts because there is much solid carbon as coke. C(s)+CO2(g)= 2CO(g) H298= 172.4
KJ/mol. As a result, following reaction occurs near the bottom part of blast furnace. 2C(s)+O2(g)=2CO(g) H298=221.1 KJ/mol. the above reaction is called combustion of coke. Two molecules in carbon monoxide as reducing gas
and 221.1 kJ in thermal energy is generated by reaction with one molecule in O2. Temperature near the tuyere of
blast furnace is 2570 K.
2.Iron oxide reduction:- Reducing reaction of iron ore (oxide) in blast furnace is classified into two kind of
reaction. One is indirect reducing reaction with carbon monoxide. The other is direct reducing reaction with solid
carbon. Direct or indirect is called whether solid coke is directly gasified. Indirect reaction occurs at the top or
middle part of blast furnace and direct reaction progresses at the bottom part. Indirect reducing reaction is written as
FeO(s)+CO(g)=FeO+CO2(g). Direct reducing reaction is written as follows: FeO(s)+C(s)=Fe+ CO(g). The
above reaction progresses at the bottom part of blast furnace where combustion of coke occurs and is endothermic.
It negatively affects the amount of energy consumption that above reaction mainly occurs. To improve carbon use
efficiency (thermal efficiency), it is important to enhance indirect reducing reaction because reducing ratio of iron
ore by indirect reducing reaction should be lifted rather than that of direct reducing reaction.
3.Coke solution-loss reaction:- The reaction C(s)+CO2(g)= 2CO(g) can also be expressed as equilibrium
reaction where Kp=p2co/pco2 , Kp is equilibrium constant. This equilibrium is called Boudouard equilibrium. The
composition of this equilibrium relates with the combustion and iron oxide reduction reactions, and dominates state
of C-O-Fe system (e.g. composition of Fe2O3, Fe3O4, FeO, Fe, CO2, CO, C and so on) in blast furnace. The
reaction toward right hand of is endothermic and is promoted with high temperature. At the bottom part of blast
furnace where the temperature indicates 2570 K, ratio of CO/(CO+CO2) is almost 1.0. At the middle part of blast
furnace, the ratio is about 0.9. This reaction at the middle part of blast furnace is, in particular, called carbon
solution-loss reaction.
Siddharth Pandey
Fe -O-H SYSTEM
Metallurgical coke not going to last long
Need alternative or at least a partial substitute fuel.
As of now, these fuels have one common aspect ,that is they have a high hydrogen content. This
hydrogen comes from crude oil ,natural gas (more hydrogen compared to coke) and from coal or coke by
the reaction of water with carbon. The process is called coal gasification .
In the blast-furnace production of pig iron, the influence of wider hydrogen application approves itself,
mainly because of the development of the injection of alternative fuels into blast furnace tuyeres.
Hydrogen contained in gases which arises from the combustion of alternative fuels in front of the tuyeres,
cooperates in the blast furnace as a deoxidizing agent and influences, not only the chemical impact, but
even, the physical properties of furnace gases.
It improves the kinetics of reducing reactions, even in small amounts. Reduction through hydrogen is
considerably less endothermic than direct reduction by carbon, which improves the heat balance of the
blast furnace. Thanks to its small density, the presence of hydrogen influences the reduction of the total
density of gas circulating through the blast furnace and the reduction of its viscosity. It leads to a decrease in
pressure loss in the furnace stack, as well as a decrease in taken out dust. In fact, hydrogen is a more
effective deoxidizing agent than CO, even at temperatures lower than 820 C, because hydrogen applies its
outstanding ability to diffuse the pores of reduced base materials.
Resulting from the above mentioned facts, besides CO and carbon, hydrogen can also be an equivalent
deoxidizing agent, not only in the blast furnace but also in the area of direct iron production from ores,
although often combined with CO.
For, Fe2O3 reduction up to iron, at the usually considered temperature of 900 C, under conditions of a
counter-current reactor, we can keep to the following scheme.
3Fe2O3 + H2 = 2Fe3O4 + H2O (1)
Possible Reactions
2Fe3O4 + 2H2 = 6FeO + 2H2O (2)
6FeO + 6H2 = 6Fe + 6H2O (3)
Ellingham Diagram
Reaction kinetics in iron ore reduction deal with the rate at which iron oxides are converted to
metallic iron by the removal of oxygen. The rate of a chemical reaction increase with increase in
temperature. For this reason the reaction kinetics are not generally a matter of great
importance in the blast furnace because of the high temperatures at which the furnace is
operated. The slowest step in the process determines the overall reaction rate and is referred to
as the rate controlling step
2.
3.
4.
5.
6.
*The rate limiting cases are chemical controlled (steps 2, 3, 5, 6) and diffusion controlled (steps 1, 3, 4)
Thermodynamics
A reaction such as FeO + CO = Fe + CO2 can occur in both the forward and backward direction under
conditions existing somewhere in the blast furnace. Delta H, Delta S, and Delta G for each reaction
are examined over a broad temperature range. These thermodynamic properties are interpreted on
the molecular level and are then used to deduce the conditions necessary for the reactions to occur
in their intended directions.
Charge :
Iron ore fines , Flux,
Non- coking coal,
Pulverized coal along with
oxygen
Principle:
The counter-current
movement of the
reducing gas produced by
coal gasification through
the fluidized bed reactors
where iron ore fines and
flux are charged.
Tejasva Vashistha
Products :
Hot
Metal(C=4.5%,Si=0.65%,S
=0.03 %), liquid slag
(basicity=1.21) , Export
gas (CO =28-30 %,
CO2=44-48% ,H2=8-12% ,
CH4=1-2 % , H2O=3-4 % )
The liquid iron is produced in the Finex process in two steps. In the first step iron ore fines is preheated and reduced to fine
direct reduced iron (DRI) in fluidized bed reactors in following stages:
The first reactor serves primarily as a reactor for preheating of iron ore fines. Iron ore fines are charged into the series of
fluidized bed reactors together with fluxes such as limestone and/or dolomite.
The iron ore fines travels in a downward direction through the four reactors where the ores are heated and reduced to
direct reduced iron (DRI) by means of reducing gas which is obtained from the gasification of the coal.
This reducing gas flows in the counter-current direction to the movement of ore. ( Fe2O3 Fe3O4 FeO Fe).
After leaving the fourth reactor, the direct reduced fines are hot compacted to HCI (hot compacted iron) and taken to a
charging bin positioned above the melter-gasifier and then charged by gravity into the melter-gasifier as per
requirement.
In the melter-gasifier smelting of the direct reduced iron ore fines takes place. Here the charged HCI is reduced to
metallic iron and melted.
Tejasva Vashistha
COREX PROCESS
BY SANDEEP SINGH
COREX: CHEMISTRY
REACTIONS IN MELTER-GASIFIER
1. Creates the reduction gas by gasifying the coal with oxygen and then cooling it.
2. Then, DRI is redirected to the char bed where the iron and slag are melted and
directed to the hearth zone.
During this process, CO and H2 gas exit the gasifier and other by-products are
captured in the metallic slag. The rest of the hot gas is then cooled and sent into
the reduction shaft, known as the Corex export gas, which is used to control the
pressure in plant.
PRODUCT ANALYSIS:
Hot Metal:
Gas:
Slag:
Suvam Das
Temperature:1430 1500 C
Uses metal bath for primary reactions to occur
Single stage process(Reduction & Melting in the same
vessel).
Non shaft type of reactor
CO(+ H2) released from the bath
Reformed natural gas is combustion medium.
used.
provides the fuel for generating
Flexibility in raw materials
3Ciron + Fe2O3 2Feiron + 3CO (highly
this heat
Coal performance has virtually no dependence on
endothermic)
Smelting occurs in the melt where the oxygen potential is particle morphology, since the coal is ground fine for
2CO + O2 2CO2
low, whereas heat generation occurs in the topspace where injection.
2H2 + O2 2H2O
oxygen potential is relatively high. The key to the process Minimized total energy consumption.
is moving heat from the combustion region down to the
Simplified engineering and process configuration
SANDEEP KUSHWAHA smelting region without compromising the oxygen
Environmental emissions well below the industry
potential in either zone.
Raw material selection along with operating parameters (e.g. hot blast
rate and level of oxygen enrichment) can be adjusted to maximize the
efficient use of the process in line with steelmaking requirements. The
ease with which the process can be started, stopped and idled provides
flexibility to the integrated steelmaker that is currently unavailable.
The Hismelt process directly injects iron ore fines (-6mm) (no
sinter, no pellets) and does not require agglomeration. The
process also requires non-coking coal (no coke making), which is
crushed and dried prior to injection into the Smelt Reduction
Vessel (SRV). A wide range of coals that are not suitable for the
Ejected slag coats the water-cooled panels, so reducing energy loss.
blast furnace can be used.
The offgas is cooled via a water-cooled hood and cleaned in a scrubber.
A variety of feed materials can be used in the Hismelt
It can be used as fuel for hot blast stoves and other equipment, such as
process, such as:
a co-generation plant.
Hematite Fine iron ores
Magnetite concentrate
The metal can be mixed directly with blast furnace iron or
Titano-magnetite ore and Iron Sands
alloyed to provide precise low silicon content for the BOF
HISMELT : Liquid Iron
Non-coking coals : Dried and ground to charge. So, compared to a blast furnace hot metal,
Smelting Reduction
3mm,
A wide range of coals can be utilized from
Hismelt hot metal:
Process
semianthracites to high volatile steaming coals
Reduces flux consumption
Steel plant wastes : Fine steel plant wastes
Increases liquid steel yield
(Charging Material &
and
metallic fines - DRI fines, mill-scale, blended
Increases productivity due to a reduced blowing time
Products )
reverts and other iron sources, BOF slag - as a flux
Produces higher quality (low phosphorus) grades
and source of iron units, Coke breeze.
Reduces re-blows reduces refractory consumption
Lower operating costs : Low cost iron making is achieved
Decreases consumption of Ferro-alloys
through the elimination of front-end processes such as coke
Allows production of ultra-clean steel.
ovens and sinter plants
not being operating
The economic performance of the process at relatively low production
commercially
capacities allows the use of multiple units to replace large blast
furnaces. This, coupled with the potential for significant increases in
productivity of each unit through raw material selection, means that
the impacts of downtime and relines can be more easily
SHUBHAM
accommodated.
The total in situ reserves of iron ore in the country are about
12,317.3 million tonnes of hematite and 5395.2 million tonnes of
magnetite.
Karnataka has the largest reserves accounting for about 26 per cent of
the total reserves of India. This is followed by Orissa (25%), Karnataka
(12%), Madhya Pradesh and Goa (17%).
It is clear from the left chart that production of iron ore and its value
had been increasing regularly over the years.
Limestone Deposits
Limestone is a sedimentary rock composed largely of the minerals calcite and
aragonite, which are different crystal forms of calcium carbonate (CaCO3).
Various deposits and production of limestone in India are as follow:
1. Sejahata in Satna district of MP
: 237.58*
2. Redipalayam in Ariyalur district of Tamil Nadu : 232.80*
3. Kota district of Rajasthan
: 236.24*
4. Kovaya in Amreli district of Gujarat
: 157.40*
5. Bastar district of Chhattisgarh
: 136.67*
6.Gulbarga district of Karntanaka
: 121.81*
*- Statistics from google latest in the year (2002-03) and the districts metioned are the
largest producer of limestone in that respective state among all the producers in it.
Ravi Kumar-13118069
Group 7
Amrutkar Rohan-13121002
Siddhant Tripathy-13410022
Amrutkar Rohan-13121002
Siddhant Tripathy-13410022
A modern blast furnace (BF) is refractory lined to protect the furnace shell from the high
temperatures and abrasive materials inside the furnace.
To achieve the goal of long lining life under stringent operating conditions, it is necessary to
have a good combination of high grade refractories.
The stack bricks are particularly exposed to high abrasion and erosion by charge material from
top as well as high velocity fume and dust particles going out due to high blast pressure in a
CO (carbon mono oxide) environment. Hence, the application condition demands refractory
materials which must have high strength, low permeability, high abrasion resistance and
resistance to CO disintegration. Super duty fireclay refractory brick or dense alumina brick
having Al2O3 around 39 % 42 % can impart these required characteristics.
The tuyere and bosh are attacked by temperature change, abrasion and alkalis; and the belly
and lower shaft by thermal shock, abrasion and CO attack etc.So, silicon carbide, SiCSi3N4 and corundum refractories are used in these zones of blast furnace.
The bottom and a part of hearth are subjected to corrosion by slag,pig iron and alkali and also
to high load and temperature.So, a refractory lining which should have high strength, lower
creep in compression value and higher RUL (refractoriness under load) . Some BFs use low
iron, dense 42 % -62 % alumina, mullite refractory bricks, conventional carbon blocks etc. in the
bottom and lower hearth.
ESHAAN KULSHRESHTHA
13118023 , GROUP-7
BAKED CARBON BLOCKS- Micro porous carbon block, semi graphitic carbon block, and micro porous
carbon silicon block are made with high temperature electrically calcined anthracite, synthetic graphite
and silicon carbide as main raw materials. They possess higher thermal conductivity, lower permeability,
good hot metal and alkali resistance.
CORUNDUM BRICKS- The corundum brick is made of brown fused corundum and silicon carbide as
starting materials, combined with special additives, through mould press process and sintering before
fine machining. It is characterized by good alkaline resistance and slag corrosion resistance which is
suitable for lining the bottom, hearth ceramic cup, tuyere, tap hole and slag hole.
ALUMINA BRICKS- 50 % alumina bricks usually have low porosity, expand upon reheating to 1600 deg C
and have good resistance to thermal cycling, They exhibit good load bearing qualities and have excellent
resistance to alkali attack.60% alumina class bricks exhibit excellent creep resistance. 70 % alumina bricks
exhibit high expansion values in service thus reducing joint sizing.80% alumina class bricks have greater
resistance to abrasion and low porosity.
FIRECLAY BRICKS- They have good refractoriness, resistance to thermal shock and volume stability at
higher temperatures, semi silica firebricks that have typical alumina contents of 18 % to 25% with silica
values ranging 72 % to 80 % and have excellent load bearing strength and volume stability at relatively
higher temperatures.
BHOOPENDRA MEENA
13118015 GROUP-7
Hot Blast
Hot blast refers to the preheating of air blown into a blast furnace or other
metallurgical process.
Large volumes of air, from 80,000 ft3/min to 230,000 ft3/min, are
generated from a turbo blower and flow through the "cold blast main" up
to the stoves to form "hot blast".
The hot blast temperature can be from 1600F to 2300F depending on
the stove design and condition.
The hot blast is directed into the furnace through nozzles called "tuyeres".
These tuyeres are equally spaced around the circumference of the
furnace. There number may vary from 14 to 40.
The hot air that is blown into the bottom of the furnace ascends to the top
in 6 to 8 seconds after going through numerous chemical reactions.
A consistently high temperature of the blast gas is critical for the efficient
operation of the blast furnace.
Rahul (13118066)
3.
BURDEN MATERIAL
Lumpy iron ore(10-40mm), in the form of hematite or magnetite or iron
oxide in the form of pellets and sinters, flux and metallurgical coke
constitute the burden materials in BF.
The average ratio of ore:flux:coke is 7:1:3 for US ores.
For achieving higher productivity, it is essential that burden material
provides high permeability and homogeneity across all furnace
temperature and reaction zones. So burden material should be porous.
Lower thickness of coke and iron ore layers help in increasing reactivity
and hence, effectiveness of BF . Composite agglomerate (RCA) and ferrocoke offer highest reactivity .
20% lumps and 80% sinter/pellets are generally used. Pellets are
expensive in comparison to sinter and are used accordingly.
The limestone is the most popular flux in blast furnace and sintering
process. The limestone charged in the blast furnace must be in lumps (2560 mm across).
Favas(13118024)
Blast furnace is conical in shape with a thicker girth at the bottom area to
accommodate a larger volume inside the bosh and belly as the hot gases are
released in this area.
The BF design is based on the concept of free standing unit with a surrounding
building structure providing access to the furnace and gas system or
supported ring system in which a lintel supports the whole furnace.
The blast furnace is 26-36 mts in height. Diameter range is 10-15 metres.
The size of various components of BF belly(2-3m)<throat(2.5-3m)<bosh(34m)<hearth(3.2-5.7m)<stack(15-21m).
The outer shell is lined with various types of refractory materials to limit the
temp rise of the furnace itself.
Some of them are fireclay bricks ,carbon bricks (used for protecting bottom of
crucible).They have basic nature.
There are tuyers below the belly for blowing hot air blast.They are generally
12-42 in number depending upon size of furnace.
Anshuman (13120007)
The price of coke has been high relative to the prices of fuel oil
and natural gas per unit of reducing capability or enthalpy and
injection of these fuels through the tuyeres has resulted in direct
cost savings .
However , recent increases in the prices of natural gas and fuel oil
have reduced this direct cost saving.
.
Shailja (13118082)
REDUCING GAS
Besides CO and carbon, hydrogen can also be an equivalent deoxidizing
agent, although often combined with CO.
The use of high-reactivity coke can decrease the reducing agent rate
(RAR).
The mechanisms by which the use of high-reactivity coke improves the
efficiency of furnace inner reactions include :
(1) control of the FeO-Fe reduction equilibrium point, or lowering of the
thermal reserve zone temperature,
(2) higher reduction ability of gas due to higher reactivity of coke
(3) accelerated ore reduction by gas due to :
(i) the reduction of FeO into Fe at lower temperatures
(ii) an increase in the volume of fine pores in ore grains
Coal is a large source of hydrogen. Thus CO along with hydrogen improves
the reducibility of iron ore.
Increasing the percentage of reducing gas increases the efficiency of blast
furnace.
Pratyush (13118061)
Method employed to extract a metal by a reduction process largely depends on its reactivity.
Iron is less reactive than carbon, so carbon can replace it from iron oxide (hematite - iron ore)
and would be easily extracted using carbon based smelting. Also, Smelting(heating with carbon)
is a lower energy process, a lot cheaper that electrolysis.
Electrolysis makes use of electricity, hence becomes very expensive process. A large amount of
electricity is required in electrolysis of iron(about 2000 kilowatt hours per tonne of iron
produced.)
Iron doesnt have great affinity towards oxygen while metals higher in reactivity series have high
affinity so their electrolysis is easier.
Iron is not usually obtained via electrolysis because it also leads to corrosion. E.g. If you subject a
water soluble salt FeCl3 to electrolysis, Fe3+ ions would migrate to the cathode, pick up 3
electrons and deposit there as iron metal which will corrode this solution.
-Kumar Vibham(13118037) &
Prithavi Chand (13118063)
Electrolysis is easier for ionic compounds which is not the case in compounds of iron
Producing iron by electrolysis rather than conventional smelting could prevent the emission
of a billion tonnes of carbon dioxide into the atmosphere every year.
So concludes Donald Sadoway, a materials scientist at MIT in the US who has developed a way
producing iron by electrolysing a molten iron oxide in the lab. If the process can be scaled
up, it could eliminate the need for conventional smelting, which releases almost a tonne of
CO2 for every tonne of steel produced.
In conventional smelting, iron ore is combined with a coal-derived carbon called coke. The
coke reacts with the iron, producing CO2 and carbon monoxide, leaving pure iron behind.
Electrolysis produces iron a different way. The iron ore is dissolved in a solvent of silicon
dioxide and calcium oxide at 1600C and an electric current passed through it. Negativelycharged oxygen ions migrate to the positively charged anode, and the oxygen bubbles off.
Positively-charged iron ions migrate to the negatively-charged cathode where they are reduced
to elemental iron which collects in a pool at the bottom of the cell and is siphoned off.
However the technology has a number of hurdles to overcome.
-Kumar Vibham(13118037)&
Prithavi Chand (13118063)
In
Sponge iron
Pig iron has a iron content of 9095% and high carbon content (5%
and more)
Non porous in nature.
Comparatively high sulphur and
phosphorus content.
Pig iron is produced by melting iron
ore under high pressure with
charcoal and limestone.
This has high carbon content and is
brittle and unstable.
The carbon dissolves in the
iron, reducing its melting point so
that it can be poured and
solidified as high-carbon ingots.
Wrought iron
Cast iron
Ankit baswal
1. ROCK DEF-Rock is a naturally occurring solid aggregate of one or more minerals which does not have a
specific chemical composition.
PURITY- contains many types of minerals so it is not pure.
STRUCTURE-sedimentary iron rocks have structures like cross bedding, graded bedding and ripple marks
PROPERTIES-porosity, coloured, lustre, texture, shape and pattern.
2. MINERAL DEF-A mineral is a naturally occurring substance that is solid and inorganic representable by a
chemical formula and has an ordered atomic structure.
PURITY- In nature, minerals are not pure substances, and are contaminated by whatever other elements are
present in the given chemical system
STRUCTURE- Minerals are typically described by their symmetry because of the geometric spatial
arrangement of atoms in their internal structure. Minerals are composed of the same substance throughout
the sample.
eg. hexagonal, tricinic, monoclinic etc..
PROPERTIES-1.hardness-controlled by the chemical composition and crystalline structure of a mineral.
2. Lustre-Metallic and sub-metallic minerals have high reflectivity like metal.
3.Color- caused by electromagnetic radiation interacting with electrons
4.Transparency
5- Streak
3. ORE
DEF-An ore is a type of rock that contains sufficient minerals with important elements including metals
PURITY- ores contain a large amount of value metal so they can directly be used for extraction purposes but
also contains some gangue or unwanted materials.
STRUCTURE- crystal structures of different iron ores are cubic, rhombohedral, orthorhombic.
4. CONCENTRATE
DEF-The desired mineral that is left after impurities have been removed from mined ore
PURITY- metal content is more than pure ore as concentrate is obtained after beneficiation.
STRUCTURE- concentrate structures just like ore structures are cubic, rhombohedral, orthorhombic.
5. TAILING METAL
DEF-The materials left over after the process of separating the valuable fraction from the uneconomic fraction
(gangue) of an ore. They are byproducts left over from mining .
PURITY- tailings consist of a slurry of fine particles, ranging from the size of a grain of sand to a few micrometres
which is a mixture of fine mineral particles and water.
STRUCTURE- They are stored in tailing ponds. the grain size varies from 0,01 mm to 1,0 mm, but up to 20 % claysized particles, i.e. 0,002 mm
PROPERTIES- Tailings generally have high water content and porosity, a low to moderate hydraulic conductivity
and a low plasticity when compared to soil.
VASANTH BALAKRISHNAN
VIJAY KUMAR VERMA
SUKHBIR
DEEPESH YADAV
MONTY BANSAL
PARVESH
PINAPALA SAI TARUN
SUSHMITA NANAWATI
(13121029)
(13120023)
(11118091)
(13118018)
(13118044)
(13118055)
(13118056)
(13118095)
UNDER GUIDANCE OF
DR.NIKHIL DHAWAN, ASSISTANT PROFESSOR IIT ROORKEE
DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING
Reduction:
Fe2O3 + 3CO 2Fe + 3CO2
Fe2O3 + 3H2 2Fe + 3H2O
Carburization:
3Fe+CO+H2->Fe3C+H20
3Fe+CH4->Fe3C+2H2
Reforming:
CH4 + CO2 2CO + 2H2
CH4 + H2O CO + 3H2
PARVESH 13118055
The principle involved in the MIDREX process is the countercurrent flow of the reducing gas
and the charge material.
The charge material is fed into the furnace from the top through seal legs and the reducing
gas enters the furnace from the bottom of the reducing zone.
CHARGING MATERIALS in MIDREX process:
Iron Ore(Lumps and Pellets-40% and 60%) , non-coking coal and Natural gas
Natural gas is used for providing combustion medium and reducing gas(CO & H2)
PRODUCTS:
Sponge Iron-DRI(Metallic Iron-83 to 86%, C-1.2to 2.5%,Oxide-5 to 8%,S-0.05 to 0.025%,P0.03 to 0.08%,Residuals-0.02 to 0.05%)
Top gas - CO2 and H2O is released at the top of the furnace.
Reactions:H2 As Gas
3Fe2O3 + H2 = 2Fe3O4 + H2O
Fe3O4+H2=3FeO+H2O
FeO + H2 = Fe + H2O
CO As Gas
3Fe2O3 + CO = 2Fe3O4 + CO2
Fe3O4 + CO = 3FeO + CO2
FeO + CO = Fe + CO2
Principle:- The HYL process in principle is not much different from MIDREX process. The main
difference is that ore is maintained in a stationary position in 4-5 of fixed beds and gas is made to
flow from one bed to another. Natural gas is converted to a mixture of CO and H2 which at a
temperature of 900- 1000 deg is passed through a bed which contains partially reduced ore, which
is reduced to metallized state. The gas from this bed is cooled to condense most of its vapour and
reheated and introduced in a bed which has less reduced ore. Operation is repeated for third bed
containing fresh hematite which is heated to reaction temperature and prereduced. Remaining
beds are charged with fresh ore or being cooled by cooling gas and metallized product is removed.
Also reaction may be carried out at increased pressure with correspondingly higher reaction rate.
Charge Material for HYL Process:Charge material is iron ore pellets and lump ore(10 to 30 mm) along with natural gas (natural
gas based HYL) or gasified non coking thermal coal( coal based HYL) at a temperature
profile ranging from 800-1050 deg C.
High methane containing natural gas is the most commonly used gas.
As the process includes a sulfur removal step, it can utilize higher-sulfur ore and gas feeds.
Products of HYL:Product obtained is high quality DRI( hot or cold) having 90-91% Fe and approx. 1.5-2.5%
Carbon, 3.5-4 % gangue impurities. It can also produce HBI( Hot Briquetted Iron).
Slag is not obtained in this process.
Hot DRI can be directly fed into EAF reducing costs of production.
1.Fe balance:
0.85 * ( 112 ) * x /160= 0.935 * 1
mass of ore, x = 1.57 tonnes
2.Flux used = 0.015 * 1 = 0.015 tonne = 15 kg
3.Carbon balance: y * 0.60 + 0.015 * ( 24 )/184 = 0.0185 * 1 + 0.935 * 1 * ( 12*3 )/(56*4)
mass of natural gas , y = 0.278 tonne = 278 kg
4.Slag = Flux + Gangue
= ( 0.015 + 0.04 ) * 1 = 0.055 tonne
mass of slag = 55 kg
Vijay Kumar Verma 13120023
4Fe + 3CO2
During continuous feeding, an active carbon oxygen boil is necessary to shield the arcs. It has been observed that to
achieve the aforesaid, sponge iron should possess a minimum of 0.6 % carbon.
High iron content, high degree of metallization and Highly reactive with moisture.
Good flowability in bins, pipes and conveyors for continuous and trouble free charging
Sponge Iron is a partsubstitute for steel scrap used for manufacturing steel by electrical arc furnaces and induction
furnaces.
Steel melting scrap is primarily required for using as a feed material in all mini steel plant that use this scrap for
melting in electric arc furnace/induction furnace to manufacture steel.
Sponge Iron is also good suitable material for using as a coolant in LD converters of the Integrated Steel Plants.
Sponge iron is created by reducing iron ore without melting it. This makes for an energy-efficient feedstock for
specialty steel manufacturers which used to rely upon scrap metal.
One of the more common uses for sponge iron is the creation of wrought iron. DEEPESH YADAV
Sponge Iron/Direct Reduced Iron (metallization and composition)-: It is the resulting product (with a metallization degree
greater than 82 percent) of solid state reduction of iron ores or agglomerates (generally of high grade), the principal
constituents of which are Metallic iron, residual iron oxides carbon' and impurities such as phosphorus, sulphur and gangue
(principally silica and alumina).
Sponge iron shall be classified into three grades based on the percentage of total/metallic iron content, the level of
impurities gangue and sulphur/phosphrous. Sponge Iron/DRI (lumps) and HBI - The chemical composition of sponge iron /DRI
and HBI shall conform to the requirements given in Table . Sponge Iron/DRI (lumps) and HBI - The chemical composition of
sponge iron /DRI and HBI shall conform to the requirements given in Table
Chemical Composition of Sponge Iron (Chemical Analysis in Percentage)
Metallization -: It is a measure of the conversion of iron oxides into metallic iron (either free, or in combination with carbon
as cementite) by removal of oxygen due to the action of the reductant used.
Degree of Metallization -: It is used to describe the extent of conversion of iron oxide into metallic iron during reduction. It
is defined as follows:
Mass of metallic iron
Degree of metallization (percent) = ------------------------ X 100
Mass of total iron
Equivalent Metallization -: Carbon content in sponge iron at a given degree of metallization is important it has the capacity
to remove oxygen from the remaining iron oxides during steel making. This leads to the concept of equivalent metallization,
which may be defined as:
Equivalent Metallization (percent) = Degree of metallization (percent)+ 5 times
the Percent of total carbon in sponge iron
SUKHBIR 11118091
Sintering
Sintering is a heat
treatment applied
to a powder
compact in order
to impart strength
Advantages
Very high levels of purity and uniformity in starting materials
After sintering the mechanical strength to handling becomes
higher.
Capability to produce nearly net-shaped objects.
Capability to produce materials of controlled, uniform porosity.
Capability to produce materials which cannot be produced by any
other technology.
No deformation needed to produce directional elongation of
grains.
Disadvantages
100% sintered (iron ore) can not be charged in the blast furnace.
By sintering one cannot create uniform sizes.
PELLETIZATION
MECHANISM
Pelletizing is a process that
involves mixing very finely
ground particles of iron ore
fines of size less than 200 mesh
with additives like bentonite and
then shaping them into
oval/spherical lumps of 8-16 mm
in diameter by a pelletizer and
hardening the balls by firing
with a fuel. It is the process of
converting iron ore fines into
Uniformed Sized Iron Ore
Pellets that can be charged
directly into a blast furnace or
ADVANTAGES OF PELLETS
Iron ore pellet is a kind of agglomerated fines which has better tumbling
index when compared with the iron ore and it can be used as a substitute for
the same both in the blast furnace and for DR production.
Pellets have good reducibility since they have high porosity (25-30%).
Normally pellets are reduced considerably faster than sinter as well as iron
ore lumps. High porosity also helps in better metallization in DRI production.
Pellets have a uniform size range generally within a range of 8 -16 mm.
Pellets have spherical shape and open pores which give them good bed
permeability.
Pellets have low angle of repose which is a drawback for pellet since it creates
uneven binder distribution.
Pellets have high and uniform mechanical strength and can be transported to
long distances without generation of fines. Further it has got resistance to
disintegration. High mechanical and uniform strength of pellets is even under
thermal stress in reducing atmosphere.
Srijan Sen(13118092,Group-13)
and a molecular bond is created between the particles. High pressures at the end of the
process cause a transition from elastic deformation of the particles to
plastic deformation, which strengthens the briquette and enables it to
retain a given shape. The physical and chemical properties of the raw material are a
major factor affecting the nature of the deformations.
Animation - https://youtu.be/L7JIOwaJZ74
Advantages
Disadvantages
Pelletization:
1