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THE FIRST BLAST FURNACE WAS BUILT IN GERMANY IN 1300 AD. BY 1850, BF OF ABOUT 18.3 M HIGH AND HEARTH DIAMETER OF 2.4 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 OF BLAST FURNACES. A BF TO PRODUCE 1900 THM/DAY WAS BUILT IN 1950. THE LARGEST BF OF THE WORLD HAVING A USEFUL VOLUME OF 5,580 CU.METRE AND HEARTH DIS OF 15.1 M WAS COMMISSIONED ON 14TH APR1986 AT THE CHEREPOVETS STEEL PLANT OF FORMER USSR. THIS FURNACE CAN PRODUCE OVER 11000 THM/DAY. THREE SMALLER BLAST FURNACE OF RSP WERE COMMISSIONED IN 1959, 1960 AND 1962 RESPECTIVELY TO
14500 C H.M TEMP AT CAST HOUSE BY-PRODUCTS LIQUID SLAG / GR. SLAG 32 - 34 % SiO2 20 22 % Al2O3 28 30 % CaO BF GAS 22 24 % CO 16 18 % CO2 2%H 56 - 58 % N CV - 850 K/CAL/M3 DUST < 8 Mg/M3 10 11 % MgO 1 % MAX FeO 0.94 % BASICITY
BF - I, II, III
1.8 MT AFTER EXPANSION IN 1970s BF - I, II, III -1000 T / DAY BF IV -1500 T / DAY
2.0 MT AFTER MODERNISATION IN 1998s BF I, II, III -1200 T / DAY BF IV -1800 T / DAY BF - IV -2200 T / DAY (AFTER MODERNISATION COMMISIONING DATES OF BLAST FURNACEIN 2005) 27.01.1959 LAST RELINING ON BF-1 = 01.11.2001 BF-2 = 10.12.2002 BF-3 = 09.09.1997 12.01.1960 LAST RELINING ON 08.01.1962 LAST RELINING ON
FURNACE PROPER
BF I,II,III PROD. CAPACITY USEFUL VOLUME WORKING VOLUME HEARTH DIAMETERS HEARTH VOLUME BOSH VOLUME NO. OF TUYERES SIZE OF TUYERS NO. OF STOVES BLAST TEMPERATURE BLAST VOLUME (MAX) 1200 THM/DAY 1139 M3 995 M3 7.4 M 129.10 M3 168.70 M3 18 140 160 MM 3/FURNACE 950oC 90,000 M3/HR. BF IV 2200 THM/DAY 1658 M3 1448 M3 9.0 M 191.0 M 227.0 M 21 140 160 MM 3/FURNACE 1000oC 160,000 M3/HR.
+ 35225
STACK COOLERS
+ 7500
1100
BLAST FURNACE
BLAST FURNACE IS A COUNTER CURRENT HEAT EXCHANGER LIQUID METAL AND SLAG ARE COLLECTED AT HEARTH. TAPPINGS AT REGULAR INTERVALS ARE DONE TO EMPTY THE FURNACE. HOT METAL IS SENT TO SMS SLAG IS SENT TO SGP / INBA / DUMP
BELT
WAGONS IRON ORE SINTER (SCREENED AT BF) COKE (SCREENDED AT BF LIME STONE / LD SLAG MANGANESE ORE QUARTZITE
STOVE S
HOT BLAST
BLAST FURNACE
BF RAW GAS
SMS-I
INPUT
OUTPUT
AIR 2.42 T SINTER 1.25 T + ORE 0.45 T LDS/LS 0.005 T QTZ. 0.001 T COKE 0.600 T
GAS 3.615 T
BLAST FURNACE
NUT COKE
SINTER
LIME STONE TI : CaO : -25mm : +50mm : MN ORE Fe : mm Mn : max. P CaO : MgO P2O5 SiO2
24 % 1 % 26 % 1 % : 0.15 : : :
LD SLAG
QUARTZITE
OUTPUT NORMS
HOT METAL Si 0.8 - 1.0 % S 0.045 - 0.05 % TEMP 14500 C AT CAST HOUSE CaO SiO2 MgO MnO FeO S 32 30 34 % 35 % 22 % 11 %
SLAG
Al2O3 20
BF GAS
OPERATING PARAMETERS
parameters BLAST PRESSURE BLAST VOLUME BLAST TEMPERATURE BLAST MOISTURE STOCK LEVEL % Sinter in Burden Fe / C TOP GAS TEMPERATURE TOP GAS CO TOP GAS CO2 BFs I, II ,III 1.15 KG/CM2 90,000 Nm3/hr. 950 DEG C 1.5 2 T/HR 1.0 M 70.0 2.0 1500 C 22 - 24 % 16 18 % BF IV 2 KG/CM2 0.8 HTP 160,000 Nm3/hr. 1000 DEG C 2 4 T/HR 0.5 M 72.0 2.0 1500 C 22 - 24 % 16 18 %
OPERATING PARAMETERS
BFs I, II ,III HOT METAL Si HOT METAL S HOT METAL TEMPERATURE SLAG RATE SLAG BASICITY NO. OF CAST / DAY COKE RATE DUST RATE 0.80 1.00 0.045 - 0.050 14300 C BF IV 0.80 1.00 0.045 - 0.050 14600 C
ROLE OF COKE
ACTS AS A FUEL ACTS AS A REDUCING AGENT SUPPORTS THE BURDEN PROVIDES PERMEABILITY IN THE BURDEN COLUMN
CROWN RING
THROAT
FUSION ZONE
1200 16000 C
DE-COMPOSITION OF HYDRATES OF IRON AND ALUMINIUM AT 3000 TO 4000 C. THE RELEASED H2O ABOVE 4000 C REST WITH CO AS H2 + CO CO2 + H2 (WATER GAS) CARBON DEPOSITION REACTION AT 4500 6000 C [ 2CO = CO2 + C + 41.2 K.CAL.) THE REDUCTION REACTIONS AT 700 9000 C 3 Fe2O3 + CO = 2 Fe3O4 + CO2 + 10.33 K.CAL Fe3O4 + CO = 3FeO + CO2 8.75 K.CAL FeO + CO = Fe + CO2 + 3.99 K.CAL DECOMPOSITION OF CARBONATES AT 900 11000 C [ CaCO3 CaO + CO2 X K.CAL] METALLOID REACTIONS COMBUSTION ZONE REACTIONS SLAG METAL REACTION
ORE
PREHEATING ZONE
TOP GAS 100 = 2500 C 10 20 % CO2 + 20 30% CO + REST N2 GAS SOLIDS 3Fe2O3 + CO = 2Fe3O4 + CO2 Fe3O4 + CO = 3FeO + CO2 INACTIVE ZONE
INDIRECT REDUCTION ZONE
COKE
GRANULAR ZONE
RACEWAY
Si & S ARE NOT DESIRABLE IN HM. Si CAUSES SLOPING IN PRINCIPLES OF IRON MAKING L.D. CONVERTER. IF RAFT IS MORE SiO2 GET REDUCED AND OTHERS METAL HAS HIGH Si & COKE RATE HIGHER. IT TEMP. IS LOW S IS HIGH IN HOT METAL FLUIDITY WILL BE LOW. INCREASING SLAG BASACITY LOWER THE SI IN HM AS CaO COMBINES WITH SiO2 TO FORM COMPLEX COMPOUNDS WHICH DO NOT GET REDUCED . THE S IN HM IS LOWERED AS CaO COMBINES WITH MnS OR FeS IS FORM CaS. INCREASE IN MNO IN SLAG LOWERS SI IN HM AS MNO COMBINES WITH SiO2 TO FORM COMPLEX COMPOUNDS WHICH DO NOT GET REDUCED. THE S IN HM IS
FURNACE & STOVES REDUCTION OF IRON ORE FORMATION OF LIQUID METAL AND FLUID SLAG REGULAR HEARTH DRAINAGE MAINTAIN METAL & SLAG CHEMISTRY & TEMP. GAS CLEANING PLANT CLEAN BF GAS MAINTAIN LINE PRESSURE OF CLEANED BF GAS SUPPLY COOLING WATER FOR BLAST FURNACES PIG CASTING M/C PROVIDE EMERGENCY OUTLET OF HOT METAL IN CASE OF OFFTAKE PROBLEM CAST OFF GRADE HOT METAL INTO PIGS
ACHIEVE 4.1 MT PRODUCTION / YEAR FROM 2010 2011 BF # 1 BF # 2 BF # 3 BF # 4 BF # 5 DAILY PRODUCTION : : : : : : 1500 T 1500 T 1500 T 2500 T 4500 T
11,500 T
SALIENT FEATURES
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. NEW FURNACE SHELL WITH A NEW PROFILE, FREE STANDING REPLACEMENT OF UPTAKES, DOWN COMERS, BUSTLE PIPE & DUST CUTOFF VALVE STAVE COOLERS IN HEARTH TO STACK + 28 MTR LEVEL INTRODUCTION OF BREAST COOLERS NEW HOT WATER PUMP HOUSE FOR OVERHEAD RETURN WATER LINES INCREASE IN BOG DEPTH OF FURNACE COMMISSIONING OF NEW GAS CLEANING PLANT WITH VENTURY SCRUBBER. NEW SKIP BRIDGE & MAIN SKIPS HIGHER CAPACITY WINCH FOR MAIN SKIPS & NEW WINCH HOUSE HIGHER CAPACITY COKE & SINTER SCREENS REVIVAL OF DEDUSTING SYSTEM
1019 9005 9539 9936 1004 10040 9760 9474 9497 9680 9258 7 0 575 166 619 179 654 189 662 191 685 198 646 187 512 148 527 152 515 150 572 174
1089 9746 1033 1077 1089 10923 1059 1013 10176 1034 1000 0 7 9 3 3 4 5 4
CONCLUSION
BLAST FURNACE TECHNOLOGY WILL CONTINUE TO SUPPLY BULK OF HOT METAL FOR STEEL PRODUCTION IN YEARS TO COME DECREASE IN COST OF HOT METAL PRODUCTION IS THE NEED OF THE HOUR AND MORE EFFORTS TO BE PUT IN FUTURE. THE ECONOMY IN BLAST FURNACE TECHNOLOGY CAN BE ACHIEVED THROUGH DEPENDING LESS AND LESS ON METALLURGICAL COKE WITH SUITABLE INJECTION TECHNOLOGY INCREASE IN CAMPAIGN LIFE OF BLAST FURNACE IS ANOTHER VERY IMPORTANT AREA OF FOCUS FOR DECREASIONG THE FIXED COST OF HOT METAL THE AUTOMIC OPERATION OF BLAST FURNACE WITH ONLINE CONTROL USING TECHNIQUES OF EXPERT SYSTEMS WILL LEAD TO STANDARDISATION OF BLAST FURNACE OPERATION AND THUS MORE STABLE OPERATION AND LESS DOWN TIME THE COST OF HOT METAL PRODUCTION CAN BE SUBSTANTIALLY DECREASED THROUGH USE OF UNDER SIZE MATERIALS IN BLAST FURNACE SPECIFIC EFFORT ARE REQUIRED TO CREATE