Burden Preparation_BF Operation Lec-10

Introduction
 The production rate of a blast furnace is directly determined by two important factors: a.
the rate of reduction of iron oxide and b. the rate of the heating
 The rate of reduction and heating of burden depends upon the degree and time of
contact of gases with the burden. The burden inside the BF should have uniform and
good bulk permeability so that equal resistance is maintained during gas flow
 The gas utilization i.e. coke rate, is a function of burden distribution. One percent
additional CO gas utilization reduce the 7 kg coke consumption for per ton or iron
 Charge materials distribution at throat plays dominant role in furnace performance
Elements of Distribution

 Various sizes, shapes and densities fall inside the furnace with various trajectories of
individual particles. Dense, small and irregular particles fall at the centre and light, large
and smooth particles roll into trough

 Coarse particles offer less resistance to gas flow while fine particle shows the high.

 Burden moves down in the furnace by slight jerks even when the operation is considered
to be smooth.

 Overlying weight pushing down the particle and friction drag with surrounding particle
varies in amount and direction.

 The system of charging, the level of the charge and the size of the charge are to be
selected so as to have maximum utilization of gas, subject to ensuring smooth
performance of the blast furnace
Factors affecting distribution

a. Design of the BF and its charging device i. Angle and size of the big bell
ii. Additional mechanical device for
better distribution
iii. Speed of lowering of large bell
b. Inconsistency of physical properties of i. Size range of the charge materials
charge materials
ii. Angle of repose of raw materials
iii. Density of raw materials
c. Level, system and sequence of charging, i. Distribution of the charge on big bell
programme of revolving the distributor
ii. Height of the big bell from the stock-
line
iii. Order and proportion of charging of
various raw materials
Distribution of charge on big bell
 Actual distribution of the raw materials on the large bell prior to drop inside, affects the
distribution in the furnace


The charge is carried out in the sequence CCOO

•The hopper is rotated through 60Oafter each skip is dumped on the small bell.
•After 8 charges (32 skips) on the big bell, is lowered to allow the hole charge fall in the furnace
(alternate charge of coke and ore on the big bell)
Order of charging
Blast Furnace Operation

1. Blowing-in
drying – new lining of BF contains a significant proportion of moisture and it is removed by
slow heating
Heating is done for 15-20 days with a lighted gas pipe for a new line and 2-3days for repaired
stoves
BF drying can be done by anyone of the following three techniques:
a. Supply of hot gas from the stove
b. Use of s Dutch oven as an auxiliary furnace to generate and supply hot gases
c. Use of wood or coke fire on the hearth

Filling:
 Filling means filling the hearth with light kindling wood and shavings saturated with oil
upto the tuyere level and laying over this a scaffold of old timber slipper
 Coke is charged above the timber scaffold
 A sufficient amount of lime stone to flux the ash of initial coke
Lighting and operating until routine practice is established:
 Furnace is lighted using red-hot bars or gas torch through the tap hole/slag hole
 Tap holes are kept open to allow the exit of the gases
 Sudden decrease in outcoming gases indicate the slag formation starts
 After nearly two days as the ratio of iron to increase in the burden
 Maximum blast furnace temperature and volume rate are achieved rather quickly to have
proper blowing-in

Blanking

 Modern BF require relinig after production of 4-6 million tonnes of pig iron.

 Temporary shutdown of a BF is known as blanking

Blowing-out
 The process of stopping the furnace operation at the end of its campaign is known as
blowing-out.