C the use of pellets in the blast furnace and the application of new technology in the ironmaking process to further reduce fuel rates per net ton of hot metal nthm. Scraps, direct reduced iron, pig iron, and additives are melted through highpower electric arcs. Level measurement in the blast furnace burden ironbearing materials and coke are transported from the bunker to the top of the blast furnace. The process of mining lowgrade iron ore, or taconite, requires massive resources. Total plant monitoring for an integrated steel plant. Steel duquesne works, west bank of monongahela river along state route 837, duquesne, allegheny county, pa drawings from survey haer pa115.
The timeline to complete the demonstration programme is about 10. There are also opportunities to recover waste heat from electric arc furnaces. Table 1 typical sulphur balance in different materials sulphur input sulphur output material kg. Available and emerging technologies for reducing greenhouse gas emissions from the iron and steel industry prepared by the sector policies and programs division office of air quality planning and standards u. Steel cost modelling notes the steel costing model the economic model shown above is prepared only to shown how liquid steel cost can be calculated through a simple cost benchmarking type approach. As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. Meanwhile, oxygen is injected into the furnace instead of preheated air to facilitate co 2 capture and storage ccs.
Today, our comprehensive range of industrial gases and costeffective technologies can help you save money throughout your operations. Energy efficiency and co reduction in the iron and steel. With design, manufacture and installation of pig iron, ferromanganese smelting blast furnace, sinter plant, hot air stove, cip system, shaft furnace, lime kiln, etc. Jul 15, 2014 since 1985, im updating a whole 67 hectares blast furnace plant. Mini blast furnace mbf is the most proven technology, as revealed by one recent global iron production data.
Xray diffraction pattern of blast furnace dust sample rourkela steel figure 3. Pdf blast furnace in engineering education researchgate. The formation of iron and steel the blast furnace 2. Stoves are also provided with waste heat recovery system and coke oven gas enrichment facilities, if coke oven gas is available. Improvements in blast furnace operation usually have significant impact on the wellbeing of the company. Groundgranulated blast furnace slag ggbs or ggbfs is obtained by quenching molten iron slag a byproduct of iron and steelmaking from a blast furnace in water or steam, to produce a glassy, granular product that is then dried and ground into a fine powder. Hopefully will have an iron blast furnace, furnace, hot air stoves, blower house, generating house, etc,coke plant, pig iron machine and slag machine. The charging of the furnace is done via conveyor belts or small aggregate wagons. C the total replacement of the open hearth process by basic oxygen and electric furnaces. The blast furnace is the primary means for reducing iron oxides to molten, metallic iron.
Other countries have introduced, or are considering. Dc arc furnace by sir william siemens the idea behind the direct current dc arc furnace has been around for a very long time. A major advance in bf ironmaking has been the use of pulverized coal which partially replaces. Emerging energyefficiency and carbon dioxide emissions. Molten iron collects at the bottom of the blast furnace and the liquid slag floats on it. Granulated blast furnace slag has a cellular structure resulting from rapid quenching in water, is cementitious in nature, and sets to form a solid concretelike mass. The blast furnace and its ancillary facilities are very complex and dynamic systems. Iron is produced by inputting coal into a blast furnace. Total plant monitoring for an integrated steel plant july 20 20, hcl technologies, ltd. The stated goal of this project is to provide a framework. Basic oxygen furnace route steelmaking costs 2020 conversion costs for bof steelmaking. The blast furnace gas bfg generated in the bf is cleaned through a series of steps primary cleaning at dust catchercyclone and secondary.
Oct 04, 2018 coal is the main ingredient used to make coke. The blast air, before entering the furnaces tuyeres air nozzles, was raised to a very high temperature by being passed through a heat exchanger or stove heated by the hot waste gasses as they left the furnace. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a fuel and reducing. Periodically both are tapped from the furnace, with the slag being solidified and recycled for use in a. Larger blast furnace, use of better prepared burden, recovery of waste energy, and maximum recovery of slag characterize the iron making technology proposed for vsp. Introduction blast furnace is the mostly applied facility for the pig. This is a major milestone in the commissioning of the state of the art sinter plant3 being constructed at a cost of rs. Mar 19, 2015 blast furnace gas it is the byproduct of blast furnaces that is generated when the iron ore is reduced with coke to produce molten iron. Blast refers to the combustion air being forced or supplied above atmospheric pressure. However, coal cannot be put directly into a blast furnace because of all the harmful byproducts that come from that. Voestalpine to test coalfree blast furnace michael pooler the austrian steelmaker voestalpine is to build an experimental facility for producing hydrogen with the aim of eventually harnessing the element to help eradicate the heavy carbon pollution that results from making steel in coalfed blast furnaces. In this case, the converter gas, which is generated by oxygen blowing process, is cleaned. What should be their competencies, qualification, experience etc.
Heavy metals, such as chromium, nickel, lead, zinc, cadmium, and mercury, belong to these unwanted elements that are inserted. Energy efficiency improvement and cost saving opportunities for the u. A high quality coke should be able to support a smooth descent of the blast furnace burden with. Hopefully will have an iron blast furnace, furnace, hot air stoves, blower house, generating house. It is narrow at the top and has an arrangement for the introduction of ore and outlet for gases. Blast furnace pellets clevelandcliffs produces various grades of iron ore pellets for use in blast furnaces as part of the steelmaking process. Firstly, the carbon in the blast furnace burns with the hot air to form carbon dioxide. While most iron ore producers mine, market and sell a commoditized product that is effectively fungible across most blast furnaces, cliffs production of custommade pellets is the true differentiating. Finex is based on the direct use of iron ore fines and noncoking coal. To the north of the blast furnace were the lime kilns, lime being part of the steel making. Sulphur removal in ironmaking and oxygen steelmaking. They are then used to help heat the air blast, required if blast furnace is to reach the high temperatures needed to produce molten iron.
A world class blast furnace operation demands the highest quality of raw materials, operation, and operators. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. Let us take a single blast furnace a 4 mt plant will have 5 to 7 blast furnaces. Files are available under licenses specified on their description page. It is therefore important for each plant to determine the optimal solutions to reduce their co 2emissions and thereby lower costs. Blast furnace smelting equipment sinter plant lime kiln.
Blast furnaces may have the following ancillary facilities. Groundgranulated blastfurnace slag ggbs or ggbfs is obtained by quenching molten iron slag a byproduct of iron and steelmaking from a blast furnace in water or steam, to produce a glassy, granular product that is then dried and ground into a fine powder. In the electric arc furnace, steel is produced only through scrap fusion. A qcp for one site would not necessarily be satisfactory for another site. These were fired by gas and a coal mixture kept in a massive concrete bunker. Can you say how many operatives at what level will be required to function at which work spots. Facilities available at blast furnace shop of rsp rourkela steel plant has 4 nos. Our products and services cover the full range of blast furnace projects ranging from complete new hot metal production plants with all auxiliary installations, furnace modernisations and relines, new or upgraded equipment and systems, plant automation and process control systems, engineering design services through to equipment maintenance and. The production of steel at an integrated iron and steel plant is accomplished using. Sinter is the most important ironcontaining feed material for the blast furnace.
The dust particles are removed from the gas flow significantly below dust concentrations of 50 mgm. The steel plant is assumed to make commodity grade carbon steel for. Steel slag produced from basic oxygen and electric arc furnaces accounted for almost all of the remainder. Extraction of iron in a blast furnace reduction haematite o. Steel homestead works, blast furnace plant, along monongahela river, homestead, allegheny county, pa photos from survey haer pa200a. Recovery of carbon and magnetite from the flue dust. Innovative uses of hydrogen in steelmaking presentation by jayson ripke, midrex technologies, inc. Pelletizing a pellet plant contains a series of balling drums where the iron ore concentrate is formed into soft pellets, in much the same manner that one rolls a snowball, to make a pellet about the size of a marble between 14 and 12. Stateoftheart computational fluid dynamics model optimizes fuel rate in. The alkali in the blast furnace form carbonates, cyanides and silicates at different temperature and heights of the furnace. This document is one from the series of foreseen documents listed below at the time of writing. This reaction produces a lot of heat, and is the main source of heat in the furnace. Description of a blast furnace plant main parts of a blast furnace, description and function composition of a charge in the production of pig iron in a blast furnace agglomeration and pelletization of iron ores requirements to individual components of a blast furnace charge time for the study. A statement regarding leachate testing for air cooled blast furnace slag.
Effective utilization of blast furnace flue dust of. Manpower assessment for new steel plant pdf download. Step 2 the blast furnace the outer case is a water cooled steel casing that provides the main support for the 30 m high furnace. The c5 furnace was built in 1942 by the defense plant corp. In a blast furnace, fuel coke, ores, and flux limestone are continuously supplied through. Step 2a the blast furnace the sinter is added through a hopper at the top of the blast furnace. At the bo ttom of the furnace, the temperature is very high. The blast furnace bf is the most widely used ironmaking. Pdf effective utilization of blast furnace flue dust of. Application of the unit this unit applies to a plant technician who has the responsibility for the operation of a blast. Environmental protection agency research triangle park, north carolina 27711 september 2012.
While gasbased as well as coalbased dri production routes produced 2. The predicted total costing shown is not meant to represent an actual cost for any real steel company. Bf route, consisting of blast furnace, sinter plant and coke oven, generating hot metal. Coke is the most important raw material fed into the blast furnace in terms of its effect on blast furnace operation and hot metal quality. Optimizing blast furnace operation to increase efficiency and. Blast furnaces in the united states wikimedia commons. Media in category drawings of blast furnaces the following 127 files are in this category, out of 127 total. Besides the transformation of the main elements iron and carbon, a large variety of other elements present at low concentrations in different input materials are undesirably inserted into blast furnaces. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper. The largest blast furnace in india at that time was of 2000 m 3. Media in category blast furnaces in the united states the following 10 files are in this category, out of 10 total. Choudhary, cmd, rinlvsp today at a glittering function held in the plant premises. One way how to intensify the process and reduce the production costs is. Media in category blast furnaces skip hoists the following 40 files are in this category, out of 40 total.
The iron ore concentrate is now mixed and ready for the pelletizing process. The cokemaking process involves carbonization of coal to high temperatures 1100c in an oxygen deficient atmosphere in order to concentrate the carbon. Behavior of chromium, nickel, lead, zinc, cadmium, and. Groundgranulated blast furnace slag is highly cementitious and high in csh calcium silicate hydrates which is a strength enhancing. The alkali metals enter the blast furnace through the raw materials. Blast furnace it is a tall cylindrical furnace made of steel. To ensure an optimal distribution of the burden and coke layers, exact level measurement is required. The cost is for a notional producer a typical size integrated bof plant, 3m tyr, at a japanese coastal site with its own coke and sinter plant, using imported ore and coal purchased at international prices with third party transport.
Its use for the bulk melting of metals dates back at least to 1878, when sir william siemens used a dc arc furnace with a vertical graphite cathode, with the arc transferred to the melt in contact with a. In 1951, we pioneered the onsite gas supply concept for the steel industry. My project is abourt coupling a gps and a 3d model to generate a video sequence, a kind of time camera which produces sequences from the past using contemporary video sequence. X ray diffraction pattern of blast furnace dust sample tata steel 3. Pmaops362a operate a blast furnace modification history release 1 new unit unit descriptor this unit of competency covers the skills and knowledge needed to operate a blast furnace.
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