BLAST

FURNAC
E

S.MEGHA
METALLURGY
5th Semester
 CONTENTS
 Introduction
 Blast Furnace constructional features
 Raw Materials in Blast Furnace
 Specifications of raw materials
 Charging of raw materials
 Blast Furnace operation
 Reactions in Blast Furnace
 Conclusion
 INTRODUCTION

STEEL

IRON

DIRECT IRON BLAST

REDUCTION SMELTING FURNACE
 What is Blast Furnace?

BLAST FURNACE is a counter current heat and mass

exchanger, in which solid raw materials are charged from
the top of the furnace and hot blast is sent through the
bottom via tuyeres.

The counter current nature of the reactions makes the

overall process an extremely efficient one.
 Construction of Blast Furnace

THROAT , where the burden surface is.

SHAFT or STACK , where the ores are heated and reduction

starts.

The BOSH parallel or BELLY.

The BOSH , where the reduction is completed and the ores are
melted down.

The HEARTH , where the molten material is collected and is cast

via taphole.
Schematic cross section of the Blast Furnace
 Basic raw materials & their functions

1. Iron ore
2. Sinter
3. Coke
4. Limestone
5. Manganese
6. Quartzite
7. Coal Dust
8. Coal tar
9. Pellets
10. Refractory
Material Chemical Analysis Specification Size
IRON ORE Fe
SiO2
64% min
2.5%
10-40 mm

P .10% max
Al2O3 .88% max

SINTER Fe 50% 5-40 mm

FeO 10%
SiO2 6%
Al2O3 3%
CaO 14-15%
MgO 4-5%

COKE Ash
VM
15-16%
.3-.4%
52-55 mm

M 5%
S .5%
C 75-80%

LIMESTONE CaO
SiO2
38% min
6.5%
6-50 mm

MgO 8.5%

LD Slag CaO 10-40 mm

MgO 40.8%
SiO2
10.5%

15.5%

Mn Ore Mn
SiO2
30% min
30% max
25-80 mm

Al2O3 5% max
P .30% max

Coal Ash
VM
9-11%
28%
90 microns

Moisture 1.80%
FC 56%
 Charging Sequence

A Typical charging sequence is given below:

Sequence 1: COC / COOCC / CCOOC
Sequence 2: CCOO

Where C= COKE ; O=NON-COKE( ore, sinter ,Mn

ore limestone or quartzite)
 Hot Blast Stoves

Air preheated to temperatures between 1000-1250°C

Delivered to the furnace via hot blast main, bustle main
and finally through the tuyeres.
Hot Blast reacts with coke and injectants, forming the so-
called raceway in front of the tuyeres.
 Reactions Involved

UPPER STACK ZONE

Reduction of oxides
Decomposition of hydrates
Carbon decomposition

MIDDLIE STACK ZONE

Direct reduction
Gas utilisation

LOWER STACK ZONE

Calcination of Limestone
Reduction of Mn,P,Zn etc
Formation of slag
 Continued…

COMBUSTION ZONE
Burning and combustion of Coke
Complete reduction of Iron Oxide
RACEWAY
Coke are oxidised
Large evolution of heat
HEARTH
Saturation of Carbon with Iron
Final reduction of Mn, Si and S
 Equipments available at the Cast house

1. Drill Machine

2. Mud gun

3. Cast house crane

4. Rocking runner

5. Pusher car
 Conclusions

Blast Furnace has now become synonymous with

extraction of iron, although it is also used for
extraction of other metals .

Years 1985 1995 2000 onwards

Blast furnace… 98% 90% 85%

DRI processes 1.5% 10% 15%

Electric smelting 0.5% .3% .3%

Other processess negligible