By ishan raina, sem :8th

BHILAI
Presented by
AVANI SHARMA

HISTORY OF SAIL BHILAI

Hindustan private steel limited started in1954
In 1957 Bhilai plant was established with
assistance from USSR having capacity 1MT.
It is fully integrated plant producing both basic
and special steel.
Ranked amongst top 10 PSU in India in terms
of turnover.

PLANT LAY-OUT

EVOLUTION OF BLAST FURNACE

TECHNOLOGY

THE FIRST BLAST FURNACE WAS BUILT IN GERMANY IN 1300 AD.

BY 1850, BF OF ABOUT 18.3 M HIGH AND HEARTH DIAMETER OF2.4
M WERE BUILT TO PRODUCE 27 THM / DAY.
BY 1900, A TYPICAL BF TO PRODUCE 180 THM/DAY WAS BUILT.
NEXT 80 YEARS, SAW A MAJOR CHANGE IN SIZE AND CAPACITY
OFBLAST FURNACES. A BF TO PRODUCE 1900 THM/DAY WAS
BUILTIN 1950.
THE LARGEST BF OF THE WORLD HAVING A USEFUL VOLUME OF
5,580 CU.METRE AND HEARTH DIS OF 15.1 M WAS
COMMISSIONEDON 14TH APR
1986 AT THE CHEREPOVETS STEEL PLANT OF FORMER USSR. THIS
FURNACE CAN PRODUCE OVER 11000 THM/DAY.
THREE SMALLER BLAST FURNACE OF RSP WERE
COMMISSIONEDIN 1959, 1960 AND 1962 RESPECTIVELY TO
PRODUCE 1000 THM/DAY. THE BIGGER FURNACE WAS
COMMISSIONED IN 1967 TOPRODUCE 1500 THM /DAY

Introduction
In the BF from top to bottom of the furnace the following
process occurs :-Drying, preheating, ejection of hydrate waterIndirect reduction-Direct reduction-Melting .
In the top third of the shaft, gas delivers its heat so that the
charging materials are preheated and dried.
When a temperature of 400C to 500C is reached, the water
which was fixed with the burden is ejected.
Indirect reduction by carbon monoxide occurs below 1000C.
At temperatures above 1000C, iron oxide not yet reduced
into iron is directly reduced. After melting, the reduction
process is completed as hot metal flows through layers of
coke.Hot metal produced in the blast furnace is sent to Basic
oxygen Furnace for steel making .

What is a Blast Furnace?

Blast Furnace is a
counter current heat
exchanger.
The purpose of a blast
furnace is to reduce and
convert iron oxides into
liquid iron called "hot
metal".
Liquid metal and slag are
collected at hearth tappings
at regular intervals are
done
to empty the furnace
Hot metal is sent to
sms/pig casting machines.

Why does Iron have to be extracted

in a Blast Furnace???
Temperature of 1800-2000C is
possible,so that carbon can reduce iron
oxide to iron directly or indirectly.
This is more efficient method than
electrolysis because it is more cost
effective

OBJECTIVE OF BLAST FURNACE

PRODUCT

HOT METAL FOR STEEL MELTING SHOP

COMPOSITION

94 % Fe
4.0 % C
0.8 % Si
0.5 % Mn
0.20 % P
0.050 % S
1450C H.M TEMP AT CAST HOUSE

BY-PRODUCTS

LIQUID SLAG / GR. SLAG

32 - 34 % Si02
28- 30 % CaO 10-11 % MgO
0.94 % BASICITY
22-24 % CO
CV - 850 K/CAL/M
56 - 58 % N

20 - 22 % Al2O3
1 % MAX FeO
BF GAS
2%H
16 -18 % CO2
DUST < 8 Mg/M3

The Method
Three substances are needed to enable to extraction
of iron from its ore. The combined mixture is called
the charge:
Iron ore, haematite - often contains sand with iron
oxide, Fe2O3.
Limestone (calcium carbonate).
Coke - mainly carbon
The charge is placed a giant chimney called a blast
furnace. The blast furnace is around 30 metres high
and lined with fireproof bricks. Hot air is blasted
through the bottom.

RAW MATERIALS FOR BLAST FURNACES

MATERIALS

SOURCE

IRON ORE

BARSUAN, KALTA, MEGHATABURU,KIRIBURU, PURCHASED

FROM OMC etc.

SINTER

SP I & SP II

LIME STONE

PURNAPANI, BIRMITRAPUR and PURCHASEDFROM OUTSIDE

Mn ORE

ROXY, BARAJAMDA, NAGPUR( PURCHASED )

QUARTZITE

PURCHASED

LD SLAG

SMS

COKE

COKE OVENS (COAL FROM DUGDA, BHOJUDIH,KARGALI,

RAJRAPPA and Imported coal)

NUT COKE

COKE OVENS THROUGH SINTER

PIG IRON
CHIPS

PIG CASTING M/C SHOP

The working of blast furnace

The Process

Several reactions take place before the

iron is finally produced...
3fe2o3 + co =co2 +2fe3 o4
at 850F

begins

Fe3o4 +co =co2 +3feo

begins

at

1100F

. feo

+ co

= co2 + fe

at 1300F

feo

c = co

+ fe

or

begins

Several reactions take place before the

iron is finally produced...
Oxygen in the air reacts with coke to
give carbon dioxide:
C(s) + O

2(g)

CO2(g)

The limestone breaks down to form

carbon dioxide:
CaCO3(s) CO2

(g)

+ CaO(s)

Carbon dioxide produced in 1 + 2

react with more coke to produce
carbon monoxide:

The carbon monoxide reduces the iron in

the ore to give molten iron:
3CO(g) + Fe2O3(s) 2Fe(l) + 3CO2(g)
The limestone from 2, reacts with the
sand to form slag (calcium silicate):
CaO(s) + SiO(s) CaSiO3(l)

Both the slag and iron are drained from the

bottom of the furnace.
The slag is mainly used to build roads.
The iron whilst molten is poured into moulds and
left to solidify - this is called cast iron and is used
to make railings and storage tanks.
The rest of the iron is used to make steel.

The blast furnace plant

High Top Pressure

Reduction of Coke rate

More wind acceptance
Better Si control
Fast drainage

Tools to improve productivity

High top pressure

High enrichment (Oxygen and auxiliary fuel)
Reduced coke rate
High percentage of prepared burden
Better distribution
Improved drainage practice
Better Raw material quality
Better sensing equipments

Conclusion:
The b/f is the 1st step in producing steel from iron
oxides.
The 1st B/f appeared in the 14th century and
produce one tons per day.now Modern,giant
furnaces produce 13,000 tons per day.
The steel industry will move toward higher value
added products in the future. In order to support
the value added steel products, iron sources have
to be secured with stable operation of furnaces.