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Thermal, Physical and Chemical: Profiles in Blast Furnace
Thermal, Physical and Chemical: Profiles in Blast Furnace
Each oxide has its own oxygen partial pressure (also known as the oxygen
potential), whose value is dependent on temperature and pressure of the system:
𝑎𝑀𝑂2 1
MO2 = M + O2 𝑝𝑂2 =
𝑎𝑀 𝐾𝑝
Shift of reaction from left to right (i.e., reduction of metal oxide MO2) can be
theoretically achieved by
(a) shift of the equilibrium by removing some of the product at constant value of 𝐾𝑝 , or
(b) reduction of the equilibrium constant 𝐾𝑝 by change of pressure or temperature of the
system.
MO2 = M + O2 1.1
R + O2 = RO2 1.3
MO2 + R = M + RO2 1.4 For the equation 1.1
0
𝑝𝑂2 𝑎𝑀
∆𝐺 = −𝑅𝑇 ln 𝐾𝑝 = −𝑅𝑇 ln ≈ −𝑅𝑇 ln 𝑝𝑂2
𝑎𝑀𝑂2
In application to reduction processes
1. if the oxygen potential of oxide is higher than one for the reductant, the
reduction of oxide occurs as MO2 + R = M + RO2
2. if the oxygen potential of oxide and the reductant are the same, the above
reaction is the sate of equilibrium
3. if the oxygen potential of reductant is higher than that for the oxide, the
reduction of oxide is impossible.
The iron reduction inside the blast furnace takes place mainly by the high
temperature scheme (i).
Magnetite (Fe3O4) is not reduced to FeO but to wüstite FeO1-y , where y has a
value of about 0.05 – 0.12.
The sum of direct and indirect reduction rates equal to unity or 100%.
Indirect reduction of iron oxide
The oxygen potential of wüstite is lower than that for magnetite. Thus, the ratio of
CO/CO2 or H2/H2O has to be higher for wüstite reduction, i.e., p > m and q > n.
For endothermic reactions (1.9, 1.10, 1.12), m, n, and q decrease with rising
temperature. For exothermic reaction (1.11), p increases with rising temperature.
Summary of indirect reduction reactions can be expressed as follows:
In the blast furnace, direct interaction between solid iron oxide and coke is negligible.
At T 950 – 1000 °C formed CO2 reacts with coke according to Boudouard reaction.
Thus direct reduction is a total reaction written according to Hess’s law.
FeO + CO = Fe + CO2 + 17.13 kJ
CO2 + C = 2CO – 172.47 kJ
FeO + C = Fe + CO – 155.34 kJ
Reduction by hydrogen at T > 950 – 1000 °C is also direct reduction, as this process
consumes coke because formed water steam reacts with coke at T > 1000 °C:
FeO + H2 = Fe + H2O – 30.86 kJ
H2O steam + C = H2 + CO – 124.48 kJ
FeO + C = Fe + CO – 155.34 kJ
In a smoothly operating blast furnace only direct reduction of wüstite takes place
because hematite and magnetite are indirectly reduced below T = 950 – 1000 °C.
Reduction of Accompanying Elements
Oxides present in blast furnace charge materials can be divided into three groups:
1. oxides which have a high oxygen potential, e.g., Mn2O3, Cu2O, NiO, are
reduced at relatively low temperatures by carbon monoxide and hydrogen
(indirect reduction);
2. oxides which have a lower oxygen potential that for corresponding iron oxides,
e.g., Cr2O3, MnO, SiO2, TiO2, are reduced by solid carbon (direct reduction).
Distribution of these elements between metal and slag depends on the oxygen
potential value: the lower the oxygen potential is, the less their rate in metal is.
For example, chromium mainly enters the hot metal, titanium is mainly lost in
the slag;
3. oxides which have a lower oxygen potential than that for carbon at
temperatures governing in the blast furnace (Fig. 1.2-Ellingham diagram).
These oxides (CaO, MgO, Al2O3) are not reduced under the blast furnace
conditions and transfer fully in the slag.
Reduction of Silicon
Silicon in the form of silica and silicates accompanies almost all charging materials.
Major sources of SiO2 are ore gangue and coke ash.
Roughly one-quarter of the SiO2 comes from coke and three- quarter from ore.
Two major routes of silicon transfer from the burden to the hot metal have been
recognised,
-from molten slag directly to molten metal
-from slag or coke ash to the gas phase in form of SiO and then into the metal.
Fresh reduced iron is a catalyst for the reaction of silica reduction and it decreases
the initial temperature of reduction down to 1050-1100 °C. Silicates of iron are
formed above the tuyere zones causing heat release, e.g.,:
Si + Fe = FeSi + 80.26 kJ (1.22)
The total reaction can be written as:
SiO2 + 2C + Fe = FeSi + 2CO – 542.24 kJ (1.23)
The main part of silicon is however reduced in the hearth from the liquid slag.
Silicon reaction above the tuyere zone (raceway) is obviously a reaction in the gas
phase. {SiO} volatilises at high temperatures and then condenses. Hypothetical
reaction sequence is:
in the hearth SiO2 + C = {SiO} + CO in absence of CO2 and FeO
in the belly 2{SiO} = SiO2 + Si
In the hearth (at T > 1100 °C) direct reduction takes place:
MnO + C = Mn + CO – 286.92 kJ (1.27)
Reduction of MnO by iron in the furnace lower zone is also possible:
MnO + Fe = Mn + FeO (1.28)
Manganese reduction is facilitated by:
high temperatures in the hearth and bosh: hotter slag and metal, high coke rate,
blast temperature, enriching blast with process oxygen;
increasing of the activity coefficient of MnO by using more basic slags; MnO
activity coefficient in the slag raises as CaO is increased and SiO2 is become
smaller;
Phosphorus recovery makes up 90 - 100 %, i.e. nearly all phosphorous enters the
metal. Therefore production of low-phosphorus metal is only possible using low-
phosphorus coke and ores. Dephosphorisation requires an oxidising atmosphere
but in the blast furnace a reducing atmosphere governs.