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Metallurgy

Is the science of producing and processing metallic materials Physical Metallurgy Mechanical Metallurgy Extractive Metallurgy

Prospects
World crude steel 1239 mTPA Indias - 49.4 mTPA

Iron & steel


Fe
Group VIII of periodic table At. No. 26 At. Mass 55.8 Ox. No +2 or +3 Biological properties

Its abundance (5.1 mass %)


high melting point transition element (phase transformation in solid state)

BCC and FCC crystal Structure


Magnetic transformation and diverse electrical properties can form alloys with around 80 other elements bond formation

BLAST FURNACE

IRONMAKING
(Present Scenario, General Features)

IRON ORE TO LIQUID STEEL


-

30 - Fe2O3

Iron ore

Oxygen %

20 -

Direct molten steelmaking Direct reduction Blast furnace Liquid steel

10 -

Scrap

0 Scrap

Remelting DRI, HBI

Carbon %

Refining Hot metal

5 -

| 0

| 200

| 400

| 600

| 800

| 1000

| 1200

| 1400

| 1600

Temperature OC

What is Blast Furnace?


A furnace in which combustion is intensified by a blast of air, especially a furnace for smelting iron by blowing air through a hot mixture of ore, coke, and flux. A blast furnace is a type of metallurgical furnace used for smelting to produce metals, generally iron. Fuel and ore are continuously supplied through the top of the furnace, while air is blown into the bottom of the chamber, so that the chemical reactions take place throughout the furnace as the material moves downward. The end products are usually molten metal and slag phases tapped from the bottom, and flue gases exiting from the top of the furnace.

BLAST FURNACE IRONMAKING


Amongst all the ironmaking processes the blast furnace still holds the dominant position. The blast furnace has remained up-to-date and competitive with the new technologies. Hot metal production rates of 8000-10,000 tpd, fuel rates of around 450-470 kg/thm (270/275 kg coke plus 175/225 kg coal) and furnace availability ranging between 95-98% are benchmarks today.

MACRO-FEATURES OF A BLAST FURNACE


The furnace is a refractory lined steel shell filled with material viz. coke, iron ore, sinter, pellets, flux, etc. from the stockline down to the bottom. The process goes on continuously for several years till the furnace is shut down for repairs and modification. The inputs and outputs are represented per metric ton (i.e. tonne) of hot metal. Preheated air above 1000-1100OC is blown through tuyeres into the furnace. It may be enriched with some pure oxygen, moisture. Most modern furnaces are practicing injection of pulverised coal as well. Exothermic combustion of coke and coal by oxygen of air gasifies carbon into CO and also provides heat. The highest temperature zone of the furnace (1900-2000OC) is at the level of tuyeres the raceway.

Counter-current gas solid reactor Solid charge (ore, coke, flux) Liquid product (hot metal + slag) Gases (blast furnace gas)

BLAST FURNACE : AUXILIARY EQUIPMENT

ZONES IN A BLAST FURNACE

DETAILS OF THE ZONES


Stack: Wall slopes outwards in downwards direction

Extends from the stock line to the mantle level. In this zone the burden is completely solid. The charge gets heated from 200C at the stock line to 11001200C at the bottom of the stack. Most of reduction occurs by gas-solid contact.

Belly: The cylindrical portion below the stack


Metallic burden begins to soften and fuse as it travels.

Bosh: Below the belly and sloping inwards in downwards direction


Burden begins to melt except coke. Gangue and flux combine to form the slag. The furnace walls are either parallel and then taper down, or are entirely tapering down resulting in reduction the sectional area by about 20-25% . This is because of decrease in the apparent volume of the charge.

Tuyere or Combustion Zone: End of slope; parallel walls


Except central column of coke, entire charge is molten. Oxygen of the blast burns coke to CO. Number of combustion zones, in front of each tuyere exists. Thus, there is a runway or race-way in front of each tuyeres which is first horizontal and then becomes vertical while expanding.

Hearth: Below the tuyere region and cylindrical


Some coke descends into hearth to form the deadman. Entire charge is molten and stratifies into slag and metal layers tapped separately.

TUYERE AREA IN A BLAST FURNACE

CONCEPT OF RAFT
From sensible heat of the flame, its temperature is calculated . This is known as Raceway Adiabatic Flame Temperature (RAFT)

Heat content of flame = Mass of gas in the flame Average specific heat of gas (RAFT 298) Change in Operating Variable
Blast temperature 1000C raised by

Change in RAFT , 0C
+82 +53

Blast oxygen raised by 1%

Blast moisture raised by 5g/Nm3


1% methane added to blast

-28
-56

HEAT BALANCE IN A BLAST FURNACE


Heat input = Sensible heat (i.e. heat contents) of the input materials (including H for changes in the states of aggregation) + Heat evolved by the exothermic reactions (measured at the reference temperature and states).

Heat output = Sensible heat of the output materials (including H for changes in the states of aggregation) + Heat absorbed by the endothermic reactions (measured at the reference temperature and states) + Heat loss to the surroundings.

BLAST FURNACES ABOVE 2000 M3 IN 2004

BLAST FURNACES IN CHINA (MOSTLY 200 TO 2000 M3)

BLAST FURNACES IN INDIA

Total

68

61

32

NEW BLAST FURNACES IN INDIA

GENERAL NOMENCLATURE OF REACTIONS IN A BLAST FURNACE


The reduction of iron oxides by CO and H2 is traditionally known as Indirect Reduction in blast furnace ironmaking. This is meant to distinguish it from the reduction by solid carbon, which is called Direct Reduction. Gas-solid reactions are much faster than reactions between two solids.

BLAST FURNACE REACTIONS


As the solid charges descend downwards, major reactions may be classified into the following categories viz.: Removal of moisture from the raw materials. Reduction of iron oxides by CO. Gasification of carbon by CO2. Dissociation of CaCO3 (where raw limestone is also added). Reduction of FeO by carbon. Reduction of some other oxides of ore by carbon. Combustion of coke and coal in front of tuyeres. The outputs from the furnace are: Molten iron (i.e. hot metal) Molten slag Gas at a temperature of around 200OC, containing CO, CO2, N2, moisture and dust particles.

SCHEMATIC OF BLAST FURNACE REACTIONS

300 C

IMPORTANT BLAST FURNACE REACTIONS


Gasification reaction: 2C + O2 = 2CO Boudouard reaction: 2CO = 2CO2 + C Solution loss reaction: C + CO2 = 2CO Water gas shift reaction: CO + H2O = H2 + CO2
Exothermic reaction

Endothermic/ Exothermic (beyond 1000C) reaction Endothermic reaction

Mild Exothermic reaction

SCHEMATIC OF IRON ORE REDUCTION

MECHANISM OF IRON OXIDE REDUCTION


Transfer of reactant gas to the solid surface (CO or H2) across the gas boundary layer around the piece of solid. 3 Fe2O3(s) + CO (g) = 2 Fe3O4 (s) + CO (g) Fe3O4(s) + CO (g) = 3 FeO (s) + CO (g) 3 Fe2O3(s) + H2 (g) = 2 Fe3O4 (s) + H2O (g) Fe3O4(s) + H2 (g) = 3 FeO (s) + H2O (g)

Inward diffusion of reactant gas through the pores of the solid chemical reaction FeO (s) + CO = Fe (s) + CO2 (g) FeO (s) + H2 = Fe (s) + H2O (g)
Outward diffusion of the product gas (CO2 or H2O) through the pores Transfer of the product gas from the solid surface into the bulk gas across the boundary layer.

BLAST FURNACE IN OPERATION

TYPICAL COST BREAK UP FOR HOT METAL


Refractories + Relining, 3-4% Labour+ Admn. , 6-7% Maintenance +Others, 7-8% Flux, 1.20%

Oxygen + Other fuel, 8-10%

Scrap + Ore, 25-30%

Coke, 45-50%

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