Jawaharlal Nehru Technological University

Hyderabad
Department of Metallurgical Engineering

BLAST FURNACE PROCESSING AND

IT’S OPERATIONS

Submitted by
-G.Ganesh Goud(16011A0609)
-A.Himashankar(16011A0613)
-K.Raghava(16011A0626)
-B.Rithik(16011A0630)
 CONTENTS
1) RAW MATERIALS SOURCE

2) BELL LESS TOP CHARGING SYSTEM

3) BASIC PARTS OF BLAST FURNACE

4) BLAST FURNACE REACTIONS

5) PULVERISED COAL INJECTION

6) TAPPING OF MOLTEN IRON

7) SLAG GRANULATION PLANT

8) OUTCOMES OF BLAST FURNACE AND THEIR COMPOSITIONS

9) CONCLUSION

10) REFERENCES
 RAW MATERIALS :

• Raw materials required for production of pig iron are Iron ore(Lumps,Sinter),
Limestone, Coke, Dolomite.

• Sinter
• Iron Ore Iron Bearing
• Coke
• Nut Coke
• PCI Fuel
• Lime Stone/LD Slag
• Quartzite/Silica Bricks
Additives
• Mn Ore
 Principle of Iron making

Iron making is essentially a reduction

process where in Iron oxide is
smelted in an reducing atmosphere to
produce the liquid iron of desired
quality.
BURDEN HANDLING SECTION

• For each furnace, there are 5 bins for sinter, 6 bins for coke. 3 bins for lump ore, 1 bin for nut
coke, 3 bins each for limestone/LD slag and quartzite used Silica bricks and manganese ore.

• Coke, sinter and iron ore are screened in screens up to 400 m3/hr capacity to remove the fines

• The screened material is fed to the inclined conveyor for burden handling to top through a
horizontal conveyor.

• Conveyor for burden handling to top are of 200 mm width 62160 m3/hr capacity and are
operated continuously.

• The materials are positioned in conveyor in separate batches at certain intervals and in a
certain sequence as per preset program.
 BURDEN HANDLING SECTION
Incoming
Conveyors

Junction
SH-1 SH-2
House

Iron Bunkers
Ore(S1-S3) BUNKERS

IRON ORE
A1

C5
A3

C6
C3
C2

C4
A2

C1

Weigh
Hoppers Screens

SINTER

MET COKE

ADDITIVES

BF
 BELL LESS TOP CHARGING SYSTEM
• It has mainly two bins having useful
volume of 47m3.
• The chute rotates at an angle of 3600
and tilts up to 540 from the vertical
axis.
• When bin 1 is receiving the
material from the conveyor bin 2
will be in discharging condition.
This way material will be charged
into B.F continuously without any
interruption.

• Bell less top valves like upper

sealing valve, lower sealing valve,
material gate, equalizing valve and
relief valves are required .

figure: BELL LESS TOP CHARGING SYSTEM

Pulverised Coal Injection

• Pulverised coal means powdered coal i.e coal fines.

• The oxygen enrichment and pulverized coal injection purpose is to decrease the
coke rate.

• Pulverized Coal is Injected into Blast Furnace through Tuyeres along with
Nitrogen(N2) as carrier gas with a pressure around 5-7 Kgcm-2 for easy ignition.
Basic parts :
 Throat,
 Belly,
 Tuyeres,
Shaft,
Hearth,
 Taphole
• The number of Tuyeres consists of blast furnaces :-

BF1=32

BF2=32

BF3=38

• The volume of blast furnaces :-

BF1 =3820m3

BF2 =3820m3

BF3 =3814m3
 Process Flow Diagram

S8 C6
C6

S7 C5
C5

S6 C4
C4
BF GAS
GCP
S5 C3
C3 Dust Catcher

S4 C2 Flue Dust

S3 C1 Stoves
Iron Ore

S2 A3

S1 A2 PCM

A1
Liquid Slag Pigs
SGP

Hot Metal
Granulated Slag

MCS SMS
Blast Furnace Reactions
 AT STACK REGION
Indirect Reactions
3 Fe2O3 + CO = CO2 + 2 Fe3O4 Begins at 850°F
Fe3O4 + CO = CO2 + 3FeO Begins at 1100°F
FeO + CO = CO2 + Fe Begins at 1100°F
Carbon Deposition Reaction
2CO=C+CO2
Dissociation of Limestone
CaCO3=CaO+CO2
 AT BOSH REGION
Direct Reduction
FeO + C = CO + Fe
Desulphurisation starts
FeS+ CaO+ C = CaS+ Fe+ CO
Combustion Zone
C+O2=CO2
Greater than 10000 C CO2 is Unstable
C+CO2 =2CO Boudard reaction
 AT HEARTH REGION
Desulphurisation Completes
FeS + CaO + C = CaS + Fe + CO
 TAPPING

 During Tapping of hot metal and slag, the closed tap hole is drilled with the
help of two drillers.One driller is used to drill the inside material of tap hole up
to the wall of Hearth and the other driller is used to drill wall of the Hearth so
that the molten metal comes out through tap hole.

 A Skimmer gate is used in runner/launder to separate molten iron and slag

according to their densities and allow them to flow in their respective runners.

 We also use silica sand and rice

husk for easy passage of molten
metal and also for easy cleaning
of launder.
 After Tapping the molten metal and slag ,Tap hole is closed with the help of MudGun
(which is produced in Masses and compound)which is in the form of piston and helps
in closing the tap hole from wall to outer surface.

 Closing of Taphole is done when combination of slag and Hot blast come from
Taphole, which indicates the furnace is dry.

MATERIALS USED FOR COMPOSITION(for 100

MUDGUN kgs)
COKE 11.13
CLAY 13.84
PITCH 6.92
SILICON CARBIDE 17.38
BAUXITE 36.92
POWDER RESIN 2.30
T-60 5.84
WASH OIL 6.15
 SLAG GRANULATION PLANT

 In Visakhapatnam steel plant for each furnace two Slag Granulation plants are
provided for each furnace either of its sides.

 Granulation unit consists or process lines, receiving bins, clarified water chambers
,granulators, air lift chambers, slag dehydrators and conveyers.

 The discharged slag is cooled in the granulator by water jets in a quantity of 2000
m3/hr at a minimum pressure of 5 atm.

 In the dehydrator the granulated slurry is dehydrated and water was removed. The
dried slag is transported to slag storage unit through conveyers

TH#6
PL#6 PL#7
TH#7

BF
TH#5
TH#8
PL#5 PL#8
 Flow chart:
Molten slag from F/C

Slag runner

Granulator Receiving bin Steam to atmosphere

HT pump Granulated slag, slurry, water

Air lift chamber

separator

Dehydrator

Dehydrated slag

Slag storage yard

 BF OUTCOMES AND THEIR COMPOSITIONS

PIG IRON SLAG BF GAS

Iron (Fe) 93.5 - 95.0% FeO 0.44-0.46%
CO 22-25%
CaO 33-36% CO2 20-22%
Silicon (Si) 0.30 - 0.90%
H2 2-5%
MgO 8-9%
Sulfur (S) 0.025 -
0.050%
SiO2 32-32.5%
Manganese 0.55 - 0.75%
(Mn) Al2O3 19.5-20%
Phosphorus 0.03 - 0.09%
(P) MnO 0.1-0.15%

Titanium 0.02 - 0.06%

CaS 0.7-0.85%
(Ti)
Carbon (C) 4.1-4.4% TiO2 0.7-0.9%
 CONCLUSION
 We observed role of different parameters like pulverised coal injection and hot blast
temperature on blast furnace production.
 Higher and constant hot blast temperature decreased coke rate and increased production rate.
 Better use of existing stoves system as influenced achieving constant and higher hot blast
temperature.
 Pulverised coal injection is used in Vizag steel plant to decrease the coke rate and increase the
production rate.

 Future Aims of Vizag steel plant(VISION 2025)

 To incerase the rate of production and to be the most efficient steel maker having the largest
single location shore based steel plant in the country.
 REFERENCES

• VIZAG STEEL PLANT REFERENCE NOTE

• Book: TUPKARY R.H., “An introduction to modern Iron Making”, Khanna

Publication