Products

1. Separation of pig iron and slag (Process &

Conditions)
2. Pig iron (composition, factors affecting
quality)
3. Slag (Properties, composition, uses)
4. Calculation for 1 ton of hot metal (how much
ore, coke, flux and slag generation)

SEPARATION OF PIG
IRON AND SLAG

Blast furnace slag is a combination of silica

and other non-ferrous components of iron
ore, ash from coke used as a reducing
material, and limestone auxiliary material.
limestone may seem unrelated to the
production of iron, but it is an essential
auxiliary material. During the process of
reducing iron ore it is necessary to remove
slag. The added limestone fuses with non
ferrous components ,lowers their melting
point making it easier to separate from iron.
Also its specific gravity is less than that of
pig iron, during the heating process the
molten slag rises above the pig iron allowing
it to be easily separated and recovered.

Ruchita Deulkar
(13118075)

Separation of pig iron and slag

Condition
The slag must have the affinity for absorbing impurities i.e. gangue from
charge along with other deleterious impurities which affect the quality of
hot metal
1) Reduction in the activity of other metal oxide .
2) Lowering the M.P. of unwanted materials .
3) Solubility :- Two phases value and slag should be immiscible into each
other.
4) Sufficient difference in the specific gravities of the two phases like slag and
metal.
5) Slag should have no solubility for metal value.
6) Slag should have sufficient fluidity
7) The melting point of the slag is to be neither too high nor too low
8) The final slag is to be fluid enough so that it is possible to drain it through
tap hole
As temperature increases viscosity decreases so fluidity increases , this shows
that temperature in blast furnace for separation process of pig iron and slag
can not be only decided by melting point of slag but also by fluidity of slag.
Md Tanveer Alam (13118043)

PIG IRON
It is the molten iron extracted from iron ore by Blast Furnace.
During the process of smelting, the liquid iron absorbs and combines with a considerable
quantity of carbon, sulphur, silicon, phosphorus, and manganese from the ore and coke.
Some of the carbon is chemically combined with the iron in the form of iron carbide, while
the remainder exists as a form of free carbon called graphite.
Compositions
Iron (Fe) 93.1 - 95.4%
Carbon (C) 3.5 - 4.5%
Manganese (Mn) 0.4 - 1.0%
Silicon (Si) 0.5 - 1.2%
Phosphorus (P) 0.15%
Sulfur (S) 0.04%
Silica and other constituents of dross(Mn ,P ,S ,etc), which makes Pig Iron very brittle and
not useful directly as a material except for limited applications.

Pig iron is graded according to the appearance of its fracture.

It is used in puddling furnaces, and more recently into steel.
Pig iron can also be used to produce gray iron.
Some pig iron grades are suitable for producing ductile iron.
Gaurav Singh (13118025)

Factors affecting pig iron qualities

Conc. Of Carbon : Increase in the concentration of carbon leads to

occurrence of graphite phase, now increase in graphite phase

increases the brittleness of pig iron and act as a source of cracks
and fracture.
Conc. Of Sulphur : Lowering the sulphur content of pig iron gives
cleaner and better cast products free from pin holes, surface dross
and improvement in mechanical properties.
Conc. Of Phosphorous: It leads to formation of steadite (Fe3P)
which solidifies at grain boundaries. Steadite is a hard, brittle
constitute which reduces toughness and ductility and cant be
eliminated by heat treatment.
Conc. Of Manganese: Mn along with S&P segregate at grain
boundaries and affect the impact strength decreases elongation
percent and also fatigue strength.
Vishal Kumar Rana (13118107)

SLAG slag is the by-product left over after a hot metal has been separated from iron ore.
Slag is usually a mixture of metal oxides and silicon dioxide.

Weight Percent (wt%)

Slag Constituent
Lime (CaO)
Magnesia (MgO)
Silica (Si02)
Alumina(Al203)
Sulfur (S)
Iron Oxide (Fe0)
Manganese Oxide (MnO)
Na2O + K2O

SLAG PROPERTIES

GLOBAL
32 to 45
5 to 15
32 to 42
7 to 16
1 to 2
0.1 to 1.5
0.2 to 1.0
0 to1

INDIAN
30 to 35
2 to 4
29 to 36
24 to 29
0.8 to 1.2
0.5 to 2.5
0.5 to 1.3
0 to1

The slag should be fluid (viscosity) so that it can be removed easily during tapping.
This ratio should be 1.1-1.2 for best slagging.
Basicity Its density is lower than that of the hot metal, so we can easily separate it.
It has good permeability (in slag formation zone) and also has appropiate melting temperature
(neither too high nor too low), Low surface tension, High diffusivity.
High internal friction values and particle interlocking properties, which gives it a higher
strength.
NITIN PATEL (13118050)
Low surface tension, High diffusivity, Oxidation potential.

SLAG APPLICATIONS

Operational uses (in blast furnace):

Shields molten steel against atmospheric

oxidation.
Acts as a thermal barrier to prevent heat
losses.
Shields the refractory lining particularly in
electric arc furnace.
Control heat transfer from the post
combustion flame.

USES (after tapping): When it is ejected

from a blast furnace, the slag is molten at a

temperature of approximately 1,500.
Depending on the cooling method used,
it is classified either as air-cooled slag or
granulated slag.

RAVI SHANKAR YADAV (13118072)

Air-cooled slag

The molten slag flows into a cooling yard, where it is

cooled slowly by natural cooling and by spraying
with water. This results in a crystalline, rock-like aircooled slag.
Common uses are as aggregates in ready-mix
concrete, precast concrete, hot mix asphalt
aggregate.
Crushed and graded - for concrete aggregates,
concrete sand, glass insulation wool.

Granulated slag

The molten slag is cooled rapidly by jets of

pressurized water, resulting in a vitreous, granulated
slag.
The principal use is as Cement replacement (when
ground), replacing 30-50% of Portland Cement in
'normal' concrete, but can replace up to 70% in
specialist applications such as marine concrete.
Other uses include, glass making, trace elements
in agriculture, concrete block manufacture.
used as raw material cast
stone, glass, fertilizer, enamel, ceramic, etc.

Mass Calculations for 1 tonne of hot metal

Mass flow diagram

Appropriate compositions have been given which are to be used in calculations :

Blast Furnace

The calculations are based on individual mass balance of different elements involved in the Blast
furnace process wherein the total elemental input from all sources is equated with total
corresponding elemental output ( product + waste ) as shown in example on next slide.
Ritvik Vipra, MMED
13118106
Kotipalli Mahitha , MMED
13118036

Mass Calculations for 1 tonne of hot metal

Coke consumption is 800Kg per tonne of hot metal.

Mass Balances:
Amount of ore
Fe- Balance:
Feore = Fehot metal
(85/100)*(112/160)* x = 1000*(95/100)
x = 1596.64 Kg = Amount of Ore required

Carbon Balance:
Ccoke + Cflux = CB.F gas + Chot-metal
0.85*800=0.95*299.37*(12/100)=CB.Fgas+0.0036*
1000
CB.F gas= 678.12 kg = 56.51 Kmoles
CO molar fraction = 28/(12+28) = 0.7
CO2 molar fraction = 12/(12+28) = 0.3
Amount of CO and CO2 present is 39.56 and 16.94
moles respectively.

Amount of flux

Amount of slag

Ca Balance:
(95/100)*(40/100)* z = y *(40/100)*(40/56)
z = 0.75 y
Al2O3 Balance:
(5/100)* x = (20/100)* y
y = 399.16 Kg = Amount of Slag
Produced
By substituting y value z can be found,
z = 299.37 K = Amount of Flux to be added

Oxygen Balance(in moles):

Oxygen supplied (with air blast) = Oxygen required to produce
CO,CO2 - Oxygen supplied through ore
= (39.56*(0.5) +16.94) 950*(48/112)*(1/32)
Oxygen in air blast = 24.01 Kmol
So ,Nitrogen in air blast =24.01*(79/21)=90.32

Total B.F Top Gas = 90.32+39.56+16.94 = 146.82 Kmol = 146.82 * 22.4 Nm3 =
3289 Nm3
Ritvik Vipra, MMED
Volume of B.F Top gas = 3289 Nm3

13118106
Kotipalli Mahitha , MMED
13118036

DIRECT(SOLID-CARBON) and INDIRECT REDUCTION OF IRON ORE IN BLAST FURNACE

Rakesh kumar,MT-3,13118067
DIRECT (SOLID CARBON
INDIRECT (GASEOUS
REACTIONS INVOLVED:REDUCTION)
CARBON REDUCTION)
Indirect reduction:Reaction between preheated and Here Fe2O3 reacts with CO with
1) 3Fe2O3 + CO = 2Fe3O4 + CO2
partially reduced FeO with solid
intermediate products Fe3O4
2) Fe3O4 + CO = 3FeO + CO2
carbon
and FeO to form Fe
3) FeO + CO = Fe + CO2

Its endothermic reaction, al

though ,It requires carbon 1/3
amount of each mole of Fe

Its exothermic reaction , but CO

comes from coke ,equilibrium
limitation prevent complete
combustion to CO

Its fuel-saving carbon reduction

As exothermic ,it yields large

thermal energy

It occurs at lower part of blast

furnace . It is responsible for 3540% reduction.

It takes place approximately in

stack. It is responsible for 6065% of reduction of ore .

Since some of the heat generated by gaseous

reduction (or more accurately by the combustion of
coke to CO) can be used to
compensate for the heat requirements of fuel-saving
carbon reduction. Both types of reaction are therefore
encountered in the blast furnace

Direct reduction:1) FeO + C = Fe +CO

Calculation in terms of coke:Indirect reduction:Fe2O3+7.5C+3.75O=2Fe+4.5CO+3CO2
2 moles of Fe:7.5 moles of carbon
So for 1 kg fe ,0.803kg of carbon
Direct reduction:Fe2O3+2.33C+3O=2Fe+1.28CO+.85CO2
2moles of Fe :2.33 moles of C
So for 1 kg Fe,0.23kg of C is required

Temperature profile of the blast furnace

It can be seen that the

softening/melting zone is located
in an area where temperatures are
between 2100 and 2600F. The
temperature differences in the
furnace are large.
Ore burden start melting at
2100F .Different iron oxide
formation depending on the
temperature is shown in the
diagram .

By Harsh Vardhan Singh

Kadiyam Yaswant Reddy ; Enrollment No.13118035;Pressure Profile of Blast

Furnace.

Pressure profile of Blast Furnace is Mainly dependent on hot blast intake velocity and amount, top
gas exit velocity and amount, amount of CO and CO2 produced in different Zones of the Blast
Furnace, the amount of CO and CO2 consumed in the reduction reactions and Boudouard Reaction
respectively and the amount of moisture levels near tuyeres that produce water gas.
Chemical Kinetics and Thermodynamics of the above processes are studied to know the Gaseous
production rates and temperatures at different Zones that govern the Pressures in different zones of
Blast Furnace.
Several mathematical models have been
developed to find the pressure profile of the
Blast Furnace. This method can be verified and
modified accordingly, further the relevance of
equations available for estimation can be
improved with experience.
Method using the analogy of gas flow to
electrical conductivity with the use of
electrically conductive paper. This method is
Time consuming but can be useful for the
zones where Mathematical Equations are
unavailable for assumptions.
The pressure profile given here is developed
using several Mathematical models and
appropriate assumptions. It is showing
minimum possible errors.

Deadman Zone
Deadman zone(coke) is the packed coke bed with dense skin structure in
the lower zone of blast furnace occupying a region extending from the
hearth up to the tuyers and a roughly conical region above the tuyers up
into the bosh
Depending on the force and pressure distribution along the lower zone of
blast furnace as well as the angle of repose for the coke bed which is
exposed towards the preheated air(with PCI,natural gas) formation of
conical shaped almost stagnant zone,deadman zone(containing pile of
coke) takes place.
Deadman coke may float or sit in the hearth depending on the force
balance between buoyancy of the coke and weight of burden actually
applied on the deadman

Madhur Gupta(13118038)

How to avoid deadman zone?

1.
2.
3.
4.
5.

Get coarse and good coke to the hearth

Large lump size of central coke (+60 mm)
High wind rate and oxygen enrichment
Reduced oil rate and possibly increased fuel rate
Reduced bottom cooling

For renewal of deadman:

cyclic movements of the bed caused by the casting cycle may help in deadman renewal
particles that enter the deadman in the centre, descend them deep down into the stagnant
bed,and then, with the up-and-down movements of the bed will lead them towards the
raceaway.

schematic showing deadman

coke

Abhishek Grover(13118003)

How to measure temperature and pressure

in blast furnace

By Divyansh Gothwal

There is an ongoing effort to reduce pig iron production cost which requires furnace productivity improvement, coke
and fuel rate reductions and longer furnace campaign life often while dealing with poorer raw material quality. To
meet the objectives and the limitations, the blast furnace process has to be transparent and it has to be modelled
accurately.

Gas flow control in blast furnace

Rishabh Thakur

Blast furnace is a counter current reactor in which the burden descends as the hot blast gasifies the
coke at the tuyeres producing carbon-monoxide which flows upwards heating and reducing the
burden materials. This gas is distributed through the coke layers in the cohesive zone and into the
granular coke and ore layers. When the burden is charged into the blast furnace, it pushes the coarse
coke particles on the top of the coke layer towards the centre . This effect is called the coke push.
The optimized gas flow in a modern furnace operated at high productivity and low coke rate has the
inverted V shaped melting zone .However the gas escaping through the ore-free centre leaves the
furnace with low utilization . This loss of unused gas should be minimised . If the central gas flow is
too high, there is a too small gas flow along the wall for heating ,reduction and melting of the ore
burden and consequently the root of the melting zone comes close to the tuyeres . In this process the
reductant rate will be high and there is high chance of tuyere damage.
Therefore it is essential that the gas flowing through the centre distributes itself through the burden
layers. Therefore the permeability of the centre coke column must not be too high , which means that
the diameter of the central coke column must not be too wide.
If the central gas flow is blocked (partially),a relatively large part of the gas escapes along the wall and
is cooled down. The result is the part of the gas is cooled down low in the furnace and the reduction
reactions slow down. In this situation, the central gas flow is small and heat losses are high . Gas flow
control is based on keeping the balance between central and wall gas flow to the optimum.

Slag-Hot metal separation

The liquid iron and slag collect in the furnace hearth

well below the tuyeres .Iron and slag do not mix:
slag has a lower specific gravity than hot iron and
floats on the iron. The implication of this is that the
droplets of iron pass through a layer of slag. Iron
and slag come close to thermal and chemical
equilibrium.
A modern blast furnace has at least two tapholes
,with furnaces as big as 14 m hearth diameter
equipped with up to 4 tapholes . The iron is cast into
the main runner system or trough . Iron and slag can
be separated easily because they do not mix due to
difference in their specific gravities . Iron and slag
flows through the main trough to a skimmer, which
allows the iron to flow through, but diverts the slag
to the slag runner .The slag is then usually
granulated by water or dumped into slag pits . The
iron is collected into torpedo ladle car(TLCs).Two
torpedoes are located at each iron runner and can
be filled using a tilting runner , which allows the
operator to exchange a torpedo during a cast.

Rishabh Parihar
Slag runners

runner
Skimmer
plate

TLC

Cast House Layout

At present Bhilai Steel Plant has 7 blast furnaces and 8th is under construction.
BLAST FURNACE No->
DIMENSION

1,2,3

4,5,6

Charging Materials
Iron ore Lumps

(Fe~64% size: 10-40mm)

Useful Volume (top

of the Hearth to
stock level)

1033 m3

Working Volume
(Tuyere to stock
level)

886 m3

Full Height , mm

28750

31250

32350

(CaO + MgO + SiO2)

14

18

24

Mn Ore

No of Tuyeres

1719 m3

2355 m3

Sinter

(Fe~50% Size:5-40mm)

Coke

1491 m3

(C:75-80% Ash:15-16%)

2105 m3

Limestone

(CaO~38%+MgO+SiO2)

LD Slag
+

(Mn:30%min Size:25-80mm)

Installation of a new furnace (BF-8) of capacity 8,030 t/d hot metal production (about 4060
m3 useful volume) at a separate location along with a new stock house and new material
handling facilities.
BSP's hot metal production is going to reach 7.5 MT per annum by its installation.

Quartzite
(SiO2 ~96% Size:25-30mm
+ Al2O3)
+

CDI Coal

(Ash:9-11% FC:56% VM:28%)

Manvendra Singh Lodha: 13118041

PRODUCTION: Production capacity of Bhilai Steel Plant is 3.153 MT of saleable

steel annually. It also specializes in production of other products such as wire rods
and merchant products.
The main Products of blast furnace are liquid hot metal and the liquid slag which is
obtained by dumping iron ore, coke and limestone from the top and preheated air
blown into the bottom.
Hot Metal : 4.080MT/year
Slag volume:
Saleable Pig Iron: 0.63MT/year
Avg.: 620.00 kg/THM
Total Hot Metal Capacity : 4.71 MT / year Range: 521 704 kg/THM

COKE CONSUMPTION:
Coke consumption is amount(in Kgs) of coke consumed per tonne of hot metal in the
Blast Furnace (kg/THM). Coke consumption rate is 450 460 Kg/THM which is
reduced by achieving maximum CDI rate. Without CDI, coke consumption is 550-650
kg/THM.
Major facilities:3 sintering machines ,7 blast furnaces, coke oven,use of CDI and
coal tar ,pellets plant,2 slag granulation plant,2 steel melting shops ,refractory,2
material plant and different mills etc.

MADE BY: NAVEEN KUMAR

ROURKELA STEEL PLANT

Rourkela Steel Plant in Rourkela, Odisha is the first integrated steel plant in the public
sector in India.
It was the first steel plant in Asia to use the LD (Linz-Donawitz) process of steel-making.
RSP presently has the capacity to produce 4.5 million tonnes of hot metal, 4.2 million
tonnes of crude steel and 3.9 million tonnes of saleable steel.
The capacity of Rourkela Steel Plant (RSP) is expected to rise to 10.8 MTPA by 2025.
There exist 5 different blast furnace of which Furnace-1 and Furnace-2 are inactive.
Furnance-1 is being re-builded and is expected to complete in 2017.
Furnace 5 Durga is the biggest blast furnace operating in the country.

Furnace 3 ,Rourkela Steel Plant

Size : Working Volume of the furnace is measured 995 cubic meters where as useful
volume is measured 1139 cubic meters.
Production : 1200 tonnes per day.
Charge Materials : Iron Ore; coke; sinter; Nut coke; Quartzite.
Coke consumption : 530 kg per tonne of hot metal.
No. of tuyeres : 18

By Diwakar Panna, En. 13118022

Furnace 4 ,Rourkela Steel Plant

Size : Working Volume of the furnace is measured 1448 cubic meters where as useful
volume is measured 1658 cubic meters.
Production : 2200 tonnes per day.
Charge Materials : Iron Ore; coke; sinter; Nut coke; Quartzite; CDI(Coal Dust Injection)
Rate of CDI consumption is 60 kg per tonne of hot metal.
Coke consumption : 476 kg per tonne of hot metal.
No. of tuyers : 21

Furnace 5 ,Rourkela Steel Plant

Size : Working Volume of the furnace is measured 3470 cubic meters where as useful
volume is measured 4060 cubic meters.
Production : 7924 tonnes per day.
Charge Materials : Iron Ore; coke; sinter; Nut coke; Quartzite; CDI(Coal Dust Injection);
and Pallet (generally used in monsoon season for 2-3 months)
Rate of CDI consumption can be maximum 200 kg per tonne of hot metal but average
is 150 kg per THM
Coke consumption : 400 kg per tonne of hot metal.
No. of tuyeres : 36

By Arpit Agrawal (13118012)

JINDAL STEEL PLANT

Founded by O.P. Jindal in 1952.
In terms of tonnage, it is the third largest steel producer in India.
Leading player in steel, power, mining, oil and gas and infrastructure in India.
Products : Rails, Wire Rods, Parallel flange beams and columns, Sponge iron, Mild steel, mild
steel slabs, ferro chrome, iron ore, structural, hot rolled plates and coils and coal based sponge
iron plant.
Steel plants in Chattisgarh, Odisha, Jharkhand.
Jindal Steel And Power Plant Jharkhand (Patratu)
6 MTPA steel plant and a 1320 MW captive power plant (CPP)
The wire rod and bar mills are equipped with the latest technology to offer superior quality
products like wire rods, TMT, rounds, angles RCS.
Blast furnace capacity: 4019 m3
Basic oxygen furnace of 2 x 200 tonne capacity
Plant Facilities:
Coke and by-product plant: 1.9 MTPA capacity
Sinter plant: 490.5 m2 capacity
Oxygen plant of 2 x 1300 tonnes/day capacity
Lime and dolomite calcination plant: 3 x 600 tonnes/day capacity
Vertika Bansal 13118104

Chattisgarh Integrated Steel Plant (Raigarh, Tamnar, Raipur)

Production Capacity: 3 MTPA steel (worlds largest coal-based sponge iron manufacturing
facility at Raigarh) and 1000 MW of thermal power at Tamnar.
Charge Material : DRI from DRI plant (1.32 MTPA).
Coke consumption is around 0.8 MTPA.
No. of tuyers : 30-32
The plant has a Coal-based sponge iron plant, Modern rail and universal beam mill, India's first
plate mill and a cement plant.
The Jindal Cement plant at Raigarh runs on slag and fly ash. The plant was established to
manage solid waste generated from steel and power plants and to process them into cement
(known as Portland Slag Cement).
Odisha Proposed Integrated Steel Plant (Angul, Barbil and Tensa)

Production Capacity: 12.5 MTPA steel and 2500 MW of power(Angul).The pellet plant
at Barbil has a total capacity of 9 MTPA. The iron ore mine at Tensa produces 3.11
MTPA sponge grade iron ore.
Coal gasification plant to produce 225,000 nm3/hr of syn gas.
Technology : DRI-BF-EAF route would be adopted for steel production.
Has a unique feature of using syn gas from the coal gasification plants as reductant.
Used for first time in the world and has the advantage of using high ash coal.
Major Facilities include : Coal washery, Sinter plant, Pellet plant, coke oven and byproduct plant, coal gasification plant, DRI plant ,BF, Steel Melting Shop, Power plant.
Pallavi Jha 13118052

TISCO Jamshedpur ,Jharkhand

The plant was built up by the famous industrialist J.N. Tata in 1907
where the production of pig iron was started in 1908 and of steel in
1911. It is the second largest and the only private sector steel plant in
the country
Description-The plant has basic open hearth furnaces, acid Bessemer
conveners and basic tilting open hearth furnaces for the manufacture
of pig iron and steel. With the help of electric furnaces it is making high
grade carbon steel which is used for structural fittings and tin plates.
Products-Railway wheels, tires and axles, bars, rods, sheets,
corrugated sheets, wires, steel castings, nails, nuts, bolts and tinplates.
Special alloy steel produced by the plant is used for making bullet-proof
armor plates and for armor-piercing bullets.

Power consumtion- 3,494.30 M.KWH

By: Rakesh Meena 13118068

Jharkhand Integrated Steel Plant (Jamshedpur)

Production Capacity (per annum):1.9 million tones of pig iron, 2 million

tones of ingot steel and 3 million tones of saleable steel
No of blast furnaces- 9(A-I)
Volume of blast furnace(avg)- 4000 cubic meter
Avg Capacity of B.F.- 2.4 mtpa to 3.15 mtpa
Charge Material(per annum)- 27.45 lakh tones of iron ore,24.45 lakh
tones of coal,5 lakh tones of limestone,2.62 lakh tones of dolomite,
90,000 tones of manganese and Ferro-manganese, and 40,000 tones of
quartzite.
Coke consumption:24.45 lakhs tones per annum
No. of tuyeres : 30-32

Proposed Integrated Steel Plant

A 6 MTPA capacity plant in Kalinganagar, Odisha, India.

An expansion of the capacity of its plant in Jharkhand from 6.8 to 10
million tones per annum.
5 MTPA capacity plant in Chhattisgarh, India .
By: Pritish Topno:13118064

1.Coaking Coal and Non-Coking Coal

2.Coal to coke process and by-products in coke oven plant
3.Impurities in coal and how to remove
4.Speciality about Australian -New Zealand coal and weathering effect

Presented by:
Brajesh kumar
Harish Parihar
Pulkit Khandelwal
Shubhankar Rajpoot
Shreya
Ankit Kumar
Anuj Agarwal

Used in manufacturing steel, where carbon must be as volatile-free

and ash-free as possible.
Coking coal is also heated to produce coke, a hard porous material
which is used to blast in furnaces for the extraction of iron from the
iron ore.
Coking coal is converted to coke by driving off impurities to leave
almost pure carbon.
The physical properties of coking coal cause the coal to
soften, liquefy and then re-solidify into hard but porous lumps when
heated in the absence of air.
The coking process consists of heating coking coal to around 10001100C in the absence of oxygen to drive off the volatile compounds.
This process results in a hard porous material - coke.
Coke is produced in a coke battery which is composed of many coke
ovens stacked in rows into which coal is loaded.
Harish Parihar

No coking properties.
Mainly used as thermal coal for
power generation.
Has a higher ash content.
Used in industries like
cement, fertilizer, glass, ceramic, p
aper, chemical and brick
manufacturing.
Indian Non Coking Coal is
classified on the
basis of Gross Calorific Value
(GCV) which
consists of 17 GCV bands.

Brajesh Kumar

This Conversion can be easily Comprehended

by an Understanding of These Zones
Different Temperature Zones for
Transformation of Coal to Coke :
1. 375 *C-475 *C - Coal decomposes
to form Plastic Layer
2. 475 *C-600 *C - Marked Evolution of
Tar and Aromatic Compounds and
Hydro-Carbons
3. 600*C-1100*C Coke Stabilization
Phase
Now this Incandescent Coke
is pushed from the Oven and then Wet
or Dry Quenched prior to its shipment
to Blast-Furnace.

Figure : Incandescent coke in the oven

waiting to be "pushed".

Pulkit

- Saturated raw gas coming from the coke oven battery contains
around 46 % to 48 % water vapour.
- Raw coke oven gas also contains various contaminants, which give
coke oven gas its unique characteristics. These consist of
1.
Tar components
2.
Tar acid gases (phenolic gases)
3.
Tar base gases (pyridine bases)
4.
Benzene, toluene and xylene (BTX), light oil and other
aromatics
5.
Naphthalene
6.
Ammonia gas
7.
Hydrogen sulfide gas
8.
Hydrogen cyanide gas
9.
Ammonium chloride
10.
Carbon di sulphide

Shubhankar

To determine the nature of coal, two types of

analysis are done:
Proximate Analysis : determines moisture
content , volatile matter ,fixed carbon and
ash.
Ultimate Analysis :determines amount of
carbon, hydrogen , oxygen ,nitrogen and
sulphur

Proximate Analysis of Indian

Coal
Carboncontent

25%
Ash
52%

Volatile
Material
18%

Moisture
2%

Ultimate analysis of Indian Coal

Ash
52%

C
31%
S
O 8%
7%

H
2%
N
0.1%

In coal , ash contains many elements

such as sodium ,potassium, sulphur
, magnesium , titanium , aluminium
and silicon.

shreya

Coal Properties can be improved by removal of impurities. Removal

of impurities is generally called Coal Beneficiation,Coal Preparation
or Coal Washing.

Two basic processes of beneficiation are:

Dry-deshaling: Non-coal or shaly-coal is removed without using
any liquid media.It is cheaper than wet process.
Separations at relatively high densities is referred
to as deshaling.
Wet Process: Coal is crushed to smaller size and put in a liquid
media of adjustable specific gravity to separate
the lighter coal (low ash) from heavier coal (high
ash). The rejects from wet process also contain
carbonaceous matter.

After all the above processes , the coal obtained would have much
less ash content and also the percentage of carbon would increase.

shreya

Australian Coal
Australia is the world's second largest
coal exporter, as it exports roughly
73% of its coal production
Mostly high-quality bituminous
coal (black coal) is found
Australia can supply the full range of
metallurgical coals. These include
traditional products such as hard and
soft coking coals as well as lower
grade metallurgical coals such as
semi-soft coking and PCI coals.
Australian coals have good coking
properties and are generally low in
Sulphur (0.3 to 0.8 per cent) and
many are low in phosphorus.

New Zealand Coal

44 % of total coal produced in
New Zealand is exported
Over 80% of the reserves are
lignite( brown coal)
Specification:
Low Sulphur
Low to medium volatile matter
Low inherent moisture
Low iron
High swell
High vitrinite content

Ankit Kumar

Disturbance to the water-saturated, oxygen-free environment of coal (before mining) ,such

as a change in the temperature, moisture content or oxygen partial pressure, will affect the
coals physical and chemical stability.
This dynamic behaviour of coal is termed weathering and includes the aerial oxidation of
the organic and mineral matter (chemical weathering), the microbial oxidation of pyrite
(biological weathering)
and changes in the moisture content that may result in particle size degradation (physical
weathering)
PROPERTY
EFFECTS
FROTH FLOTATION

The effectiveness of processes such as froth flotation and oil

agglomeration is largely reduced.

CALORIFIC VALUE

Calorific Value decreases. High rank coals may be only slightly

affected, whereas in low rank coals the effects may be severe.

COKING
PROPERTIES

Decreases : The coking value of coal is likely to be destroyed after a

period of 3 years. Coke reactivity also increases when weathered coal
is used and this is detrimental to the operation of blast furnaces.

SULPHUR CONTENT

Total sulphur in coal decreases with increased weathering. This is due

to sulphate sulphur being leached from the coal.

MOISTURE
CONTENT

Inherent moisture content decreases

VOLATILE CONTENT

Decreases

Anuj Agarwal

Furnaces
Group -12

Group members
Alisha Anil Manwar 13120012
Amandeep Singh 13118006
Anu Garg 13214004
Divyanshu Gupta 13118021
Ravi Raj 13118071
Satyendra Kumar Tiwari 13121021
Seth Riddheish Anilkumar 13118080
Shubham Jain, 13118089
.

Rotary Kiln -Introduction

Rotary kiln refers to rotary calciner, belongs to building material equipment. It can be divided into cement rotary
kiln, metallurgy rotary kiln and lime rotary kiln.
Rotary Kiln- Working Principle
Rotary kiln is made of steel plate, and inside the kiln body inserts refractory lining, which keeps specified inclination with
horizontal line. Rotary kilns are used to heat solids to a predetermined temperature in order to create a chemical and/or
physical reaction. The two basic types of rotary kilns direct fired and indirect fired .

Material is fed into kiln from kiln tail. Due to the slope and rotation of the cylinder, the material make a composite
motionit rolls in circumferential direction and at the same time moves in axial direction.
After sintering process, the material is calcined in cement clinker and discharged into cooler machine through kiln head
hood, prayed into the kiln from the kiln head, the fuel burns in the kiln, after exchanging with the material, the generated
waste is discharged from kiln tail. The burner in this design is excluding fuel

ROTARY KILN PROCESSES

Torrefication, Pyrolysis (Thermolysis), Carbonisation, Gasification, LTC (Low Temperature

Conversion),Calcination, Drying, Cooling.
Anu Garg

TYPES OF ROTARY KILNS

NOVEL APPROACH

USAGE OF ROTARY KILN FOR

TYPE 1: Counter current rotary kiln; TYPE 2: Co-current rotary kiln RECLAIMING NICKEL BY FEECO
By using rotary kilns to generate
COUNTER CURRENT ROTARY COCURRENT ROTARY KILN
high processing
KILN
1.Flue gases flow in the same
temperatures, FEECO created an
1.Flue gases flow in the
direction of the waste, with
innovative recycling method that
opposite direction of the
the inclination of the kiln.
eliminated unnecessary organic
waste, against the inclination
material while recovering valuable
of the kiln.
minerals. The customer was able to
2. Mass reduction (%) > 86 %. 2. Mass reduction (%) > 76 %.
reclaim nickel from waste
3. Fly ashes:760 mg/Nm3.
3. Fly ashes:1700 mg/Nm3.
materials, prevent toxic materials
from entering the
environment, and promote a
sustainable and profitable material
solution.

Advantages:

1. The rotary kiln has the function of the heat exchanger. The rotary kiln has the homogenous
temperature field.
2 The installation of the excellent combustion apparatus can ensure the full combustion of the fuel,.
3. With the different needs of cement clinker minerals in the different stages, it can not only meet the
heat exchange and temperature requirements of different minerals in different stages, but also can meet
their requirements on time.
4. Because the rotary kiln has high temperature field and thermal field stagnation air time long,
biodegradable chemical, pharmaceutical, etc discharge of poisonous and harmful waste.

ALISHA ANIL MANWAR

13120012

SHAFT FURNACE:
Structure and principle-It is a vertical refractory lined cylinder in which a fixed bed or descending column
of solids is maintained ,and through which an ascending stream of hot gas is forced .The shaft furnace
works on counter current principle where the iron ore feed material moves downward in the furnace by
gravity and gets reduced by the up flowing reducing gases.
Notable examples- pig iron blast furnace, phosphorous(from phosphate rock) furnace.
Types- Shaft furnaces can either be static or tilt able (tilting model, where the shaft is static is possible too).
Operation based on principle-Moderate velocities of the gaseous combustion products are characteristic of
shaft furnace. The bulk of the lumped materials(the charge) s not entrained by the ascending gas stream
and, in contrast to the fluidised bed furnace, maintains aerodynamic stability. The counter-current motion
of the charge (top to bottom) and of the gases forced through the charge(bottom to top) and the direct
contact between the charge and hot gases result in good heat exchange and generation of low
temperature exhaust gases.
Consequently, shaft furnaces are characterized by a high thermal efficiency and a relatively high output. So
such furnaces are widely used to smelt iron ores and in non-ferrous metallurgy of Ca,Ni etc.
Parts of Simplified Shaft furnace shown
alongside:
(1) charging device
(2)gas outlet
(3)Tuyere
(4)outside crucible
(5)slag notch
(6) matte hole
(7) inside crucible
-Seth Riddheish Anilkumar , 13118080

Can be designed for

non-ferrous material
like Ni, Al and for
non metals like P.

Longer
lifetime
than other
furnaces

Applicable for
different scrap
qualities

Advantages of Shaft Furnace

Fast and
continuous
melting

Slag can easily

be tapped out

Optimized thermal
efficiency with
atleast 40% lower
energy consumption
than other furnace.

EXAMPLES :1. Pig Iron Blast furnace

2. Cupolas (A cupola or cupola furnace is a melting device used in foundries that can be used
to melt cast iron. The cupola can be made almost any practical size).
3. Aluminium shaft melting furnaces (Shaft geometry and especially adapted burner
technology process steps such as preheating, heating and liquefaction can be combined in
one melting shaft. The molten material is added in a cold state in the shaft, sinks down the
shaft and is heated up during sinking. Ascending flue gasses resulting from the melting
process are cooled, i.e. the shaft furnace functions in a favorable counter flow principle
relating to warmth. The molten material flows without turbulences and dross to holding
room where the selected tapping temperature is maintained).
-Shubham Jain, 13118089

Rotary Hearth Furnace :

Principle and Working :
The RHF consists of a flat, refractory hearth
rotating inside a stationary, circular tunnel
kiln.
Inside the RHF, direct reduction of iron ore or
iron-bearing byproducts occurs, using coal as
the reductant.
The feed to the RHF consists of composite
agglomerates made from a mixture of iron
oxides (virgin ore or by-products) and a
carbon source such as coal, BF dust, charcoal
or other carbon-bearing solid.
The temperature is controlled by means of
burners positioned along the walls and roof of
furnace .For optimized heating quality the
annular furnace peripherically divide into
several temperature control zones : The
Preheating zone , Heating zone and uniform
heating zone
Hearth and reducing gas rotate in opposite
direction to reduce pellets / briquettes to
metallic Iron at temperature around 1300 c .

Sketch of Rotary Hearth Furnace

Satyendra Kumar Tiwari

13121021

ADVANTAGES :
Production of DRI(Direct Reduced Iron). Carbon source can be coal, coke fines, charcoal,
or other carbon-bearing solid.
Work flexibility and high reliability. High temperature uniformity :Suitable for heat
treating large quantities of the same parts. Furnace atmosphere easy to control and High
superheating power .
Overpressure control . Economical and Safe operations : Low consumption of
technological mediums . Easy service and maintenance.
High quality parts : no scale and decarburization .High repeatability of processes : Fully
automated and quick loading and unloading of the load .Used for various treatment
processes such as case hardening and carburizing (low case depth), neutral hardening,
reheating, tempering, annealing etc.
EXAMPLES :
FASTMET : Coal-based iron oxide reduction process. Uses a rotary hearth furnace to
convert steel mill wastes and iron oxide fines to highly metallized DRI. Extremely energy
efficient.
FASTMELT : Uses a rotary hearth furnace but adds an electric iron melting furnace for
production of a high quality hot metal known as FASTIRON . Can convert poor quality iron
ores and non-coking coals into quality pig iron products.
FASTEEL : More environmentally friendly as merging of the hot metal producing benefits
of FASTMELT with the continuous scrap feeding and preheating of CONSTEEL to produce
high quality steel.
FASTOx : High quality steelmaking for areas without economic scrap supplies, or clients
with pre-existing BOF equipment . Can use locally available iron ore fines and non coking
coals, coke fines, or charcoal.
ITmk3 : Processing iron ore fines into almost pure pig iron nuggets in only ten minutes.
Supply pig iron grade nuggets directly to the EAF steelmaking industry.
Amandeep Singh 13118006 MT-1

Fluidized Bed
Essentially consists of a main column in which the iron ore coal
mixture is fluidized at high velocity and a return column in which
the entrained solids from the main column are collected via a
cyclone. Solids from the return column are re-circulated to the
bottom of the bed in the main column through a control valve.
Fast bed conditions prevail in the main column and the solids in
the return column constitute the slow bed. Solids are
continuously fed in at the top of the reactor and enter the slow
bed through the cyclone. During this descent, the solids get
preheated by the rising gases. Partial reduction of the higher
oxides of iron also takes place.
The fluidized bed reactor operates at 400- 450 C temp. and 46
atm pressure. High pressure is required to produce non sticky
and un-sintered iron powder and increase reaction rate.
Conversion of iron oxide 98%
Hydrogen utilization 5% thus necessating recirculation of exit
gas after drying.
Highly pyrophric iron product is treated with N2 at 81- - 870C
before storing
Applications in powder metallurgical and briquetting industries.
Typical dimensions of 50 tpa rector: 1.7m OD and 29m height.
Approx .051 - .056 ton of H2 and .25 ton of O2 reqd. to process
1.4 ton of high grade magnetite to arrive at 1 ton of iron
Reaction aspects:

Schematic diagram of circulating fluidized bed reactor

Generation of gaseous reductants

For reduction of iron oxide

Divyanshu Gupta
13118021

Fluidized Bed
Advantages of Fluidized Bed

Application & Examples

The smooth liquid like flow of particle

allow continuous automatically controlled
operation with case of handling .
Rapid mixing of solid leads to nearly
isothermal condition through the
reactor, hence the operation can be
controlled simply and reliably.
It is suited to large scale operation .
Circulation of solid between two fluidized
beds makes it possible to transport the
waste quantities of heat produced or
needed in reactors
Heat and mass transfer rates between gas
and particles are high when compared
with other modes of contacting.
The rates of heat transfer between a
fluidized bed and immersed object is high
hence heat exchange within fluidised
within fluidized bed requires relatively
small furnace area.

Solid-Catalysed Gas Phase Reaction

Fluid Catalytic Cracking Reforming

Phthalic and Maleic Anhidride

Oxidation of so2 and so3

Polyethylene and Polypropylene

Chlorination and Bromination of Hydrocarbon

Gas-solid Reaction
Roasting of ores(Zns, Cu2S, sulphide ores)
Combustion and incinerations
Calcinations(limestone ,phosphates, aluminium, hydroxide)
Reduction of iron oxide
Fluorination of uranium oxide
Gasification, coking, and Pyrolysis / Carbonization
Gas- Phase-Non catalytic reaction
Natural gas combustion
Gas liquid solid
Hydro treating and hydro processing
Biochemical process
Physical processes
Drying of particle
Coating of surfaces

RAVI RAJ

EN-13118071

Flue gas (composition, temperature, uses)

in Blast Furnace

Flue gas is a by-product of blast furnace that is generated when the iron
ore is reduced with coke to metallic iron. It has a very low heating value.

Composition:
CO2 :18-20%, CO :24-27%, H2 :3-5% and N2 :55-57%(approximately)

Temperature:
The temperature of flue gas as it leaves the furnace is 120-3700C.
This pressure is utilized to operate a generator (Top-gas-pressure Recovery Turbine - i.e.
TRT in short), which can generate electrical energy up to 35 kwh/t of pig iron without
burning any fuel.

Uses:

It is used as a fuel to preheat the air blast in blast furnace.

Preheated BF gas along with preheated air has been used successfully in coke-oven
heating, soaking pits, and reheating furnaces.

Flue gas is used for many applications in a steel plant and, in addition, is used
Made by:
frequently for heating coke ovens.
Babita Bala (13118014),
Shraddha Suman (13121025)

It is normally being used mixed with either coke oven gas or converter gas or both.
The mixed gas is used as a fuel in various furnace of the plant.
Flue gas without mixing and without preheat can be used in -

1.

Normalizing and annealing furnaces

2.

Blast Furnace stoves

3.

Foundry core ovens

4.

Gas engines for blowing

The thermal advantage of using flue gas in gas engines for blowing
and for power generation has to overcome the heavy investment and
maintenance expense required for such equipment.
5. Boilers for power generation
The modern boiler house utilizes high steam pressure and
temperature with efficient turbo-blowers and generators. This
has
sufficiently reduced the thermal advantage of gas engines and hence their use
has become difficult to get
justified.
6.Gas turbines for power generation.
Made by:
Babita Bala (13118014),
Shraddha Suman (13121025)

BLAST FURNACE GAS CLEANING SYSTEMS

Because of the presence of substantial amount of CO in the BF flue gas, it has a considerable
amount of calorific value and thus is utilized in hot blast stoves (for preheating hot blast),
power plants and gas engines. However, for
efficient use, gas has to be cleaned of the dust
g
(consisting of fine burden particles).
Initially, separation methods using water (wet
methods) were implemented. At present, a
combination of dry and wet methods is being
used. The advantage The dust separated via
dry method can be again sent for sintering
and fed in the Blast Furnace.
DRY METHODS: Primarily use equipment called
Dust-Catchers.
Gravity Dust-Catcher: The flue gases are
allowed to interact with some ascending gases
so that the dust particles attain a terminal
velocity and get separated.
Schematic diagram of BF gas cleaning system

KN Sasidar(13118034)

 Cyclone Dust-Catcher: The separation mechanism is based on the action of centrifugal forces on the dust particles. The
gas is introduced through two tangential inlets (into a kind of shaft) with a velocity to force the dust particles to the
wall and separate them from the gas stream.

WET METHODS
After primary separation in the dustcatcher, or cyclone, the blast furnace top gas is scrubbed with water in the annular
gap scrubber to obtain has a single tower construction comprises the pre-scrubber/cooler and the annular gap
scrubber stages, and is followed by a high-efficiency, external moisture separator. The characteristics of the annular gap
scrubber are: Multiple dust removal mechanisms, Minimum scrubbing water requirements and Superior top pressure
control. The principal separating mechanisms in an annular gap scrubber are: Inertial interception, Turbulent
(Brownian) diffusion and Flow line interception.

Inertial interception : characterised by the different inertial forces of the varying masses. When the dust-laden gas flows

around the collecting water droplet, the dust particles of larger mass do not follow the flow lines of the gas stream. These
particles, propelled by the inertia force, strike and penetrate the water droplet, and thus are removed from the gas stream.

Turbulent diffusion : highly effective in removing smaller dust particles from the gas stream. Small particles, particularly
those below about 0.3m in diameter,exhibit considerable Brownian movement and do not move uniformly along the gas
streamline. These particles diffuse from the gas stream to the surface of the water droplets and are collected. This collection
mechanism can only function in scrubbers that promote turbulent flow of a gas-liquid mixture, operate at low velocity and
provide sufficient retention time.

Flow-line interception : It only functions if the gas streamline passes within one particle radius of the collecting water

droplet. The dust particle travelling along this streamline will touch the water droplet and will be collected.

A cyclone followed by an annular gap scrubber offers High dust removal efficiency of 85% or higher and to a guaranteed value
of 5mg/Nm3, minimum water requirement as the annular gap scrubber operates with a low and constant water-to-gas
ratio, reduction the size of the water recycle system and thus minimising energy consumption, suit it up for installations for
low top pressure furnaces as well as for installations with top gas energy recovery turbines.
Made by Apurva

Gas Recycling

The concept of the Top Gas Recycling Blast Furnace relies on separation of the off gases so that
the useful components can be recycled back into the furnace and used as a reducing agent. This
would reduce the amount of coke needed in the furnace. In addition, the concept of injecting
Oxygen (O2) into the furnace instead of preheated air, removes unwanted Nitrogen(N2) from the
gas, facilitating Carbon dioxide(CO2) Capture and Storage (CCS).
CCS plays an important role in Gas Recycling:
A promising technology for significantly reducing the CO2 emissions from the blast furnace is to
recycle reducing gases (CO and H2) leaving the furnace with the top gas. The re-use of these
reducing gases lowers the usage of fossil carbon (coke). To reclaim them, however, the CO2
needs to be removed from the top gas, recycling the remaining gas back into the furnace. In
addition, to avoid build-up of N2 in the furnace, the blast furnace needs to be operated with pure
oxygen, instead of hot blast. For reaching a 50 % CO2 emissions reduction target, CCS
technology is necessary to store the captured CO2.
Prepared
by:
Vikram
Kumar
(13118105)

Gas Generation

In blast furnace, gas generated occurs as by-product when iron ore is reduced to molten iron
(Fe). The operation of the blast furnace is controlled to produce hot metal of a specified quality
and during this production BF gas comes out from the furnace top. Around 1500-1700 cu-m/ton
of hot metal of BF gas is generated during the process.
CO2 and CO generation:
When the hot air blast is blown in the furnace through
the tuyeres, Oxygen in the air reacts with coke to give
carbon dioxide
C(s) + O 2(g) CO2(g) H= -58230 J
then the limestone breaks down to form carbon dioxide
CaCO3(s) CO2 (g) + CaO(s) H= 41800 J
Carbon dioxide produced reacts with more coke to
produce carbon monoxide
CO2(g) + C(s) 2CO(g) H= 41500 J
The CO/CO2 ratio can vary in a blast furnace from
1.25:1 to 2.5:1. Higher percentage of CO in the gas
makes the BF gas hazardous.
HCN and CN2 generation:
In blast furnace some hydro cyanide (HCN) and Cyanogen gas (CN2) can also formed due to the
reaction of nitrogen in the hot air blast and carbon of the coke. The reaction is catalyzed by the
alkali oxides. These gases are highly poisonous.
Rohit(13118074) and Jasjot(13118033)

H2 and CH4(water gas) generation:

Methane (CH4) can also be present in the BF gas up to 0.2% and H2 is around (3-5)%.
Any moisture present in the hot air blast also reacts
with the carbon of the coke. This reaction consumes
heat and produces more reducing gas which is a
mixture of CO and H2. Hence where high blast
temperatures are available (1000 deg C to
1200 deg C), the following reaction is favorable.
C+H2O=CO+H2 H= 31400 J
The advantage of above reaction is that there is
the introduction of hydrogen gas in the furnace
reducing gases which decreases of the density
of ascending gases.
N2 generation:
Nitrogen is not generated in the blast furnace by any chemical reactions but, Nitrogen
from the air pass up through the furnace as fresh feed material travels down into the
reaction zone.
H2S and COS generation:
Sulphur enters the blast furnace mainly in coke and is released into the blast furnace
gas stream either as H2S or a gaseous compound of carbon monoxide and sulphur
(COS) when the coke is burned.
FeO + COS = FeS + CO2
Jasjot(13118033) and Rohit(13118074)

IMPURITIES IN ORE
Main impurities in iron ore are silica, phosphorous, sulphur, alumina
SILICA: Silica is the most common impurity. This is because of the
physical contrast between silica-rich minerals, like quartz, and iron-rich
minerals
PHOSPHOROUS: Phosphorous is one of the nasty impurities in iron ore. It
results in brittle iron. It is not easy to remove phosphorous so it is
preferable that ores are low in phosphorous to start
SULPHUR: Like phosphorous, sulphur is an impurity to avoid in iron ores.
High sulphur ores (>0.01-0.03%) are to be avoided as it ultimately
makes iron brittle, prone to cracking and failure.

ALUMINA: Alumina is another common impurity in iron ores. This reflects

its abundance in many other minerals which might also be included
RAVI KANT
with the iron ore minerals.
12118065
GROUP 11

Coke is a fuel and reducing agent in Blast Furnace with few impurities and
a high carbon content, usually made from coal.
It is the solid carbonaceous material derived from destructive
distillation of low-ash, low-sulphur bituminous coal.
Impurities present in coke are ash(inorganic residue after burning),
Sulphur, Phosphorous and other volatile matter.
Ash usually contains refractory oxides like SiO2,Al2O3,CaO,etc..
Phosphorous and Sulphur are also present in ash in the form of inorganic
compounds.
Coal available in India contains 2-7% of sulphur in it.
All the Phosphorous and some part of sulphur goes into the pig iron.
Sulphur in the coke requires additional flux for its removal or else sulphur
content of iron goes up.
Ash combines with the flux and is removed as slag.
Shaik Syed Akram
13118081

Where do the impurities in flux (CaCO3) go?

The most frequent impurities in limestone are dolomite ,silica ,alumina , clay minerals
, and the oxides and hydroxides of iron and manganese, as well as pyrite, phosphates,
and organic matter .
There are other trace elements that are present in limestone are sulphur ,
phosphorus, arsenic, manganese and fluorine.
Phosphorous gets completely into molten iron.
Molten Iron consists of 0.4-0.6 % Si , 0.1-0.2 % P , 0.040-0.050 % S , 0.1-0.5 % Mn.
Alumina ,Silica , MgO , 0.1-1.2% Mn and 1-2% S goes into Slag.
Other volatile materials are removed as gases.
Anugu Shashank
13121003

BASICS

The mix charged into a

blast furnace comprises
Haematite (Iron ore
mainly Fe2O3)
Limestone CaCO3
Coke (source of C)

HOW TO REMOVE IMPURITIES

The limestone removes the silica

as calcium silicate and phosphorus
as phosphate which is called SLAG.
This is molten and less dense than
molten iron so floats on top. This
has the advantage of preventing
oxidation at the iron surface. The
slag is tapped off periodically, and
run off the surface of the iron.
USES OF SLAG
Slag is used in road making and as
"slag cement" - a final ground slag
which can be used in cement,
often mixed with Portland
cement.

The most annoying

impurities for an iron
maker are
Silicon
Phosphorus
Carbon (in high levels)

The amount of carbon

impurities in the iron is
controlled by adding
more or less coke at the
top and also by
controlling the length of
the blast of air coming
through at the bottom.
The air will burn off the
excess C
Equations (Main ones)
CaCO3 ===> CaO + CO2
SiO2 + Ca O ==> CaSiO3
C + O2 ===> CO2
C + CO2 ===> CO
Fe2O3 + 3CO ===> Fe (l) + 3CO2

Zinc Removal
ZnO from ore and coke gets reduced to Zn,
which cyclically vaporizes and condenses in
top parts of BF, thus builds up
Removal ensured by allocation in BF slag
and top gas (higher gas temp and higher gas
velocity, higher Zn content)
Controlling at sinter stage by adding NaCl or
CaCl2 during sintering which affect
evaporation of Zn
Phosphorus Removal
P2O5 gets completely reduced to
P. Therefore, virtually all of the
P in the burden materials will
dissolve in the hot metal.
Lakshman N. Chakrav
13120013

Sodium Removal
Na2O from ore gets partially reduced
to form Na vapor, builds up by
vaporization and condensation cycle
Vapor removed by maintaining central
gas flow, Na2O removal favored by
forming low-basicity slag
Sulphur Removal
S in form of FeS, gets reduced in
presence of CaO, in hearth (at very
high temp.)
Governing reacton:
FeS + CaO + C = Fe + CaS + CO2
Removal depends upon hearth temp,
slag basicity, slag volume

Effect of alumina and silica on BF Productivity

Alumina and Silica came from coke (ash) ,ore (gangue) and limestone . These are major constituent of
gangue and ash and minor constitute of limestone . All amount of alumina will go to slag phase where
as some part of silica will get reduced ,go to molten metal and rest will go to slag. High content of
alumina in slag make Al2O3 : SiO2 ratio also high and reduce the iron productivity in BF.
Alumina are deleterious because more amount of it increase the melting temperature of slag and
make it more viscous . Thus more fuel consumption in BF and reduce productivity of BF.
At high temperature FeO is in molten state and it become more reactive . Hence, FeO react with Silica
(presents in flux/gangue) and form FeO.SiO2.
This FeO.SiO2 less activity then FeO so it is difficult to reduce . It require limestone to convert into FeO.

FeO.SiO2 + CaO --> CaO.SiO2 + FeO

If Fe is rich in ore but it is siliceous ( elemental Si present ) the value of ore is reduced and lowers
productivity of BF.
Hemlata borana

Agniva Si
13118005

FURNACE IRREGULARITIES

For a stable and efficient operation of a blast furnace, smooth and uniform movement of burden materials downward and movement of furnace gases in the
upward direction is very important. In spite of these improvements, the blast furnace does not run as smoothly as one is led to believe. Furnace upsets are not
as frequent as they were in earlier years but irregularities still do occur.

IRREGULARITIES

REMEDIES

Leaky Tuyeres

A leaky tuyere results usually from wear or from local superheating or " burning" of the metal,
whereby the cooling water is allowed to leak into the furnace hearth. If the leak is not promptly
discovered and stopped, it may result 'in serious cooling of the hearth

The maintenance instructions for tap holes must be

scrupulously followed to minimize these
turbulence.

Furnace
Hanging

When the materials charged at the top of the blast furnace do not move continuously towards
the hearth of the furnace, the phenomenon is called hanging of the burden. Hanging of the
burden material in the blast furnace stack occurs when the material below the hang continues
to move downward, forming a space that is void of materials but filled with gas at very high
pressure.

Add limestone of large size which forces the

solution loss reaction to take place and thereby
improves the permeability of the bed. Hanging
furnace responds to colder blast. Blow down the
furnace to bosh level and filling it with coke blank.

Slipping

The collapsing of the hang is a phenomenon called slipping during which the charged materials
fall uncontrollably toward the hearth of the furnace in a thermally unprepared state which leads
to the furnace getting cold. The sudden rush of gases opens the furnace top gas bleeder and
sometimes can cause top equipment damage.

Allow BF to slip on its own by adjustment of the BF

temperature and pressure. Bad bosh design may
cause slipping and bosh behavior of burden
materials needs to be assessed before the design.

Channeling

The phenomenon of channelling happens when the ascending gases in the furnace does not
properly get uniformly distributed both radially and circumferentially in the furnace and find a
passage of least resistance. The different causes for channelling to occur in the blast furnace are
charging of excessive fines, improper distribution of the burden material inside the furnace.

Use of a more uniformly sized burden and proper

distribution can minimize this. Channeling
otherwise reduces the effective cross section.

Scaffolding

The term scaffolding is used when accretions or scabs build up on the furnace walls and cause a
decrease in the cross sectional area of the stack of the blast furnace. Scaffolding can occur
relatively at the higher level of the stack of the blast furnace or relatively low in the stack, near
the top of the bosh.

Minimize : Alkali content of the burden,

refractoriness of the slag, erratic working of
furnace, decrease in fuel rate, shut-offs of blast for
any reason. Charge few blanks of coke and reduce
the BF pressure on the affected sides.

IRREGULARITIES

REMEDIES

Chilled
Hearth

Affects tapping adversely as tap holes are blocked. It may result because of low
fuel input, excessive moisture in the blast, water leaking from tuyeres, etc.
Slipping can also cause chilling.

Gas torches can be used to open the tap holes.

The metal may even be tapped through the
cinder notch if possible.

Breakout

These are caused by failure of the bosh walls or hearth walls or hearth bottom
with the result that the liquid iron or slag or both flow out of the furnace in an
uncontrolled fashion.

A properly designed hearth with minimum of

refractory joints and absence of continuous
straight joints up to the shell can minimize this.

Pillaring

Blast is unable to penetrate right up to the center of the furnace, this leads to
the formation of a cold central column of the stock with an annular hot zone
around it.

It can be eliminated by increasing the blast

pressure which will penetrate more and heat up
the pillar.

Choking of
Gas Offtake

Furnace operation has to be suspended if dust gets accumulated in the uptakes

and downcomer and it can be resumed only after the clean-up.

Care should be taken so as there are no faulty gas

offtake designs, particularly the inadequate cross
section and improper joints.

Flooding

An increase in the gas or liquid flow can prevent the liquid metal and slag from
flowing downwards, causing it to accumulate in the coke interstices until the
weight of the liquid overcomes the upward thrust of the gases and descends
suddenly into hearth.

This can be minimized by having a high voidage

i.e. by using higher mean size of the coke. Better
quality coke is also beneficial.

The interruption in uniform blowing rate causes the raceway to collapse and
when it is resumed again the small particles of coke can not re-enter the
raceway and consequently descend into the hearth, instead of burning in the
tuyeres region, resulting in a choked hearth.

Uniform blowing of the furnace is the best

remedy to avoid this.

Coke Ejection

In general, immediate detection and correction of any irregularity is essential to avoid serious troubles
and loss of output.

Mayank Jain
13118042

PHYSICO-CHEMICAL ASPECTS OF
BLAST FURNACE
(GROUP- 3)

Zones in a blast furnace

HEARTH:
Hearth is that part of furnace where
the molten product (i.e., molten metal
and slag) of the blast furnace
accumulate and stay there until these
are tapped periodically.
The slag is tapped every 2-3 hours
and the metal is tapped every 5-6
hours in a normal practice.
Process must operate at minimum
temperature (in hearth) i.e., operating
temperature of the blast furnace will
have to be more than liquidus
temperature of the slag formed.

TUYERE:
Coke is the only constituent of the
burden that descends down into the
tuyere zone in the form of a solid
column.

Pranav B. 13118057
Nitin kant 13118049

The main reactions in the tuyere area is the STACK:

combustion of coke i.e.,
The functions of blast furnace are 2 fold.
C + O2 CO2.
Firstly it should progressively reduce the
But in the presence of excess coke reaction
iron oxide to iron using CO and secondly it
should extract sensible heat from the
CO2 + C
2CO takes place thereby
ascending gases and thereby get itself
amounting the overall process as
heated.
2C + O2
2CO.
There is always some moisture in the blast Reactions:
3Fe2O3 + CO
2Fe3O4 + CO2
that reacts with hot coke in tuyere area as
Fe3O4 + CO
3FeO + CO2
H2O + C
CO + H2.
oC

At
temperature
greater
than
570
BOSH:
FeO + CO
Fe + CO2.
The reduction of iron oxide by the CO
content of the ascending gases and directly Besides of reduction of iron oxide, higher
oxide reduce to lower oxide as,
by solid coke or carbon deposited by the
MnO2 + CO
MnO + CO2
Naumann Reversion continues and goes to
completion in the bosh region.
Mn3O4 + CO
MnO + CO2
Softening also occur while descending Further reduction of MnO to Mn is
through the bosh zone.
possible only by carbon at higher
temperature level.
Reactions in the bosh zone of blast furnace:
SiO2 + 2C
Si + 2CO
THROAT:
FeS + CaO + C
CaS + Fe + CO
The region where the burden surface
P2O5 + 5C
2P + 5CO
exists.
MnO + C
Mn +CO

In blast furnace, any fraction of the components is governed by thermodynamic equilibrium state in C-O-Fe system
and reaction kinetics caused by the difference between actual and equilibrium state. The Fe-C-O system can be
broken down into three steps.
1.Combustion (reducing gas generation):- In blast furnace, carbon atom of coke reacts with oxygen
molecule from tuyere.
C(s)+O(g) =CO2(g) H298 = -393.5 KJ/mol. Where H is the heat of formation of the reaction. Generated carbon
dioxide by above reaction reacts because there is much solid carbon as coke. C(s)+CO2(g)= 2CO(g) H298= 172.4
KJ/mol. As a result, following reaction occurs near the bottom part of blast furnace. 2C(s)+O2(g)=2CO(g) H298=221.1 KJ/mol. the above reaction is called combustion of coke. Two molecules in carbon monoxide as reducing gas
and 221.1 kJ in thermal energy is generated by reaction with one molecule in O2. Temperature near the tuyere of
blast furnace is 2570 K.
2.Iron oxide reduction:- Reducing reaction of iron ore (oxide) in blast furnace is classified into two kind of
reaction. One is indirect reducing reaction with carbon monoxide. The other is direct reducing reaction with solid
carbon. Direct or indirect is called whether solid coke is directly gasified. Indirect reaction occurs at the top or
middle part of blast furnace and direct reaction progresses at the bottom part. Indirect reducing reaction is written as
FeO(s)+CO(g)=FeO+CO2(g). Direct reducing reaction is written as follows: FeO(s)+C(s)=Fe+ CO(g). The
above reaction progresses at the bottom part of blast furnace where combustion of coke occurs and is endothermic.
It negatively affects the amount of energy consumption that above reaction mainly occurs. To improve carbon use
efficiency (thermal efficiency), it is important to enhance indirect reducing reaction because reducing ratio of iron
ore by indirect reducing reaction should be lifted rather than that of direct reducing reaction.
3.Coke solution-loss reaction:- The reaction C(s)+CO2(g)= 2CO(g) can also be expressed as equilibrium
reaction where Kp=p2co/pco2 , Kp is equilibrium constant. This equilibrium is called Boudouard equilibrium. The
composition of this equilibrium relates with the combustion and iron oxide reduction reactions, and dominates state
of C-O-Fe system (e.g. composition of Fe2O3, Fe3O4, FeO, Fe, CO2, CO, C and so on) in blast furnace. The
reaction toward right hand of is endothermic and is promoted with high temperature. At the bottom part of blast
furnace where the temperature indicates 2570 K, ratio of CO/(CO+CO2) is almost 1.0. At the middle part of blast
furnace, the ratio is about 0.9. This reaction at the middle part of blast furnace is, in particular, called carbon
solution-loss reaction.
Siddharth Pandey

Fe -O-H SYSTEM
Metallurgical coke not going to last long
Need alternative or at least a partial substitute fuel.
As of now, these fuels have one common aspect ,that is they have a high hydrogen content. This
hydrogen comes from crude oil ,natural gas (more hydrogen compared to coke) and from coal or coke by
the reaction of water with carbon. The process is called coal gasification .
In the blast-furnace production of pig iron, the influence of wider hydrogen application approves itself,
mainly because of the development of the injection of alternative fuels into blast furnace tuyeres.
Hydrogen contained in gases which arises from the combustion of alternative fuels in front of the tuyeres,
cooperates in the blast furnace as a deoxidizing agent and influences, not only the chemical impact, but
even, the physical properties of furnace gases.
It improves the kinetics of reducing reactions, even in small amounts. Reduction through hydrogen is
considerably less endothermic than direct reduction by carbon, which improves the heat balance of the
blast furnace. Thanks to its small density, the presence of hydrogen influences the reduction of the total
density of gas circulating through the blast furnace and the reduction of its viscosity. It leads to a decrease in
pressure loss in the furnace stack, as well as a decrease in taken out dust. In fact, hydrogen is a more
effective deoxidizing agent than CO, even at temperatures lower than 820 C, because hydrogen applies its
outstanding ability to diffuse the pores of reduced base materials.
Resulting from the above mentioned facts, besides CO and carbon, hydrogen can also be an equivalent
deoxidizing agent, not only in the blast furnace but also in the area of direct iron production from ores,
although often combined with CO.
For, Fe2O3 reduction up to iron, at the usually considered temperature of 900 C, under conditions of a
counter-current reactor, we can keep to the following scheme.
3Fe2O3 + H2 = 2Fe3O4 + H2O (1)
Possible Reactions
2Fe3O4 + 2H2 = 6FeO + 2H2O (2)
6FeO + 6H2 = 6Fe + 6H2O (3)

By- Ananya Shrivastava

Ellingham Diagram

> Sumanyu Parashar

Sharma (13118093)
> Tarun Borana
(13118098)

Ellingham Diagram is the plot between the Gibbs free energy

of a reaction and temperature. For a reaction to be feasible at
a particular temperature, the sum of G for its constituent
reactions should be negative.

The relationship between Gibbs free energy and

temperature is given by:
G = H - TS

Fig : Ellingham Diagram for oxide

formation

Since H and S are essentially constant with

temperature unless a phase change occurs, the free
energy vs temperature plot can be drawn as a series
of straight lines; where S is the slope and H is the yintercept. Phase change causes change in slope. For
reactions occurring in a blast furnace, free energy of
formation is negative for oxides and G=0 at the top
of the diagram. The values of G shown are negative.
Slope depends on value of S (upwards if positive,
downwards if negative).

The temperature at which the line for the

oxidation of reducing agent falls below
that of oxidation of metal to metal oxide,
is the temperature required to be
maintained for reduction and is a
measure for the ease of reduction.
The reduction of ore in a blast furnace
occurs in various steps at specific heights
in the furnace, corresponding to specific
temperatures. These can be tallied with
temperatures found for the reactions to
occur from the Ellingham diagram for the
blast furnace.
Coke is a good reducing agent for iron
oxides since it is forms CO which is
responsible for most of the reduction
taking place in the blast furnace. Also, it is
economical and has the required
mechanical strength. Direct reduction of
FeO also takes place to some extent.

> Sumanyu Parashar

Sharma (13118093)
> Tarun Borana
(13118098)

Fig : Reactions occurring in temperature

zones of a blast furnace in accordance
with the data obtained from the
Ellingham diagram

Kinetics & Thermodynamics

Vivek Singh (13118108)

Ujjwal Kumar Gupta

Reaction kinetics in iron ore reduction deal with the rate at which iron oxides are converted to
metallic iron by the removal of oxygen. The rate of a chemical reaction increase with increase in
temperature. For this reason the reaction kinetics are not generally a matter of great
importance in the blast furnace because of the high temperatures at which the furnace is
operated. The slowest step in the process determines the overall reaction rate and is referred to
as the rate controlling step

Rate Laws in Reduction

1.

Transport of gaseous reductant from the

bulk gas phase to the particle surface
through a boundary gas film.

2.

Reaction at the interface (reaction between

adsorbed reductant and oxygen of the
lattice).

3.

Mass transport of iron and oxygen ions and

transformations in the solid phase,
formation and growth of reaction products.

4.

Molecular diffusion of gaseous products

through the product layer to the particle
surface.

5.

Adsorption of the gaseous reductant at the

interface.

6.

Desorption of the gaseous products from

the interface.

*The rate limiting cases are chemical controlled (steps 2, 3, 5, 6) and diffusion controlled (steps 1, 3, 4)

Thermodynamics

Vivek Singh (13118108)

Ujjwal Kumar Gupta

A reaction such as FeO + CO = Fe + CO2 can occur in both the forward and backward direction under
conditions existing somewhere in the blast furnace. Delta H, Delta S, and Delta G for each reaction
are examined over a broad temperature range. These thermodynamic properties are interpreted on
the molecular level and are then used to deduce the conditions necessary for the reactions to occur
in their intended directions.

The reactions of the blast furnace involve :

1) Combustion of the fuel and its conversion into CO2
2) Reduction of the ore
3) Formation of slag

The sign of G indicates if a reaction is thermodynamically

spontaneous at a particular temperature. The familiar
equation G = H TS reminds us that spontaneity is
determined primarily by H at low temperature, but that
S becomes important at high temperature. Strictly
speaking, G is the test of spontaneity only for a reaction
conducted at standard conditions. When nonstandard
conditions must be considered, we will examine the
equilibrium constant for the reaction. It can be calculated
from the equation G = -RT ln K.

Fig : G vs. Temp. for

the three steps in the
reduction of iron ore
by CO. Each curve
applies to a different
reaction. For example,
the curve labeled
Fe2O3 Fe3O4 is for
the reaction 3 Fe2O3 +
CO 2 Fe3O4 + CO2

ALTERNATIVE IRON MAKING

TECHNOLOGIES
GROUP -13
FINEX TEJASVA VASHISTHA

FASTMELT SAIKAT DEY & VARTHA KOTA SAI DINESH

COREX SUVAM DAS & SANDEEP SINGH

HISMELT SHUBHAM GUPTA & SANDEEP

KUSHWAHA

Charge :
Iron ore fines , Flux,
Non- coking coal,
Pulverized coal along with
oxygen
Principle:
The counter-current
movement of the
reducing gas produced by
coal gasification through
the fluidized bed reactors
where iron ore fines and
flux are charged.

Tejasva Vashistha

Products :
Hot
Metal(C=4.5%,Si=0.65%,S
=0.03 %), liquid slag
(basicity=1.21) , Export
gas (CO =28-30 %,
CO2=44-48% ,H2=8-12% ,
CH4=1-2 % , H2O=3-4 % )

PROCESS & REACTION STAGES:

The liquid iron is produced in the Finex process in two steps. In the first step iron ore fines is preheated and reduced to fine
direct reduced iron (DRI) in fluidized bed reactors in following stages:

The first reactor serves primarily as a reactor for preheating of iron ore fines. Iron ore fines are charged into the series of
fluidized bed reactors together with fluxes such as limestone and/or dolomite.
The iron ore fines travels in a downward direction through the four reactors where the ores are heated and reduced to
direct reduced iron (DRI) by means of reducing gas which is obtained from the gasification of the coal.
This reducing gas flows in the counter-current direction to the movement of ore. ( Fe2O3 Fe3O4 FeO Fe).
After leaving the fourth reactor, the direct reduced fines are hot compacted to HCI (hot compacted iron) and taken to a
charging bin positioned above the melter-gasifier and then charged by gravity into the melter-gasifier as per
requirement.
In the melter-gasifier smelting of the direct reduced iron ore fines takes place. Here the charged HCI is reduced to
metallic iron and melted.

Advantages of the Finex process:

It can use Iron ore fines of size 0-12 mm and with high alumina content. It can use iron ore fines without blending.
The process uses non coking low ranked coals. Coal fines can also be used in the process after converting them
into briquettes. The process can accept coal lumps and coal briquettes in the ratio of 60:40.
The process has independent control of reduction and melting process and is environment-friendly with low SOx
emissions.

Tejasva Vashistha

COREX PROCESS

BY SANDEEP SINGH

Fig.- Corex process

COREX: CHEMISTRY

REACTIONS IN REDUCTION SHAFT:

Similar to the blast furnace process, the reduction gas moves in
counter flow to the descending burden in the reduction shaft.
Then, the reduced iron is discharged from the reduction shaft by screw
conveyors and transported via feed legs into the melter gasifier.
1. Reduction of iron oxide by CO and H2 to metallic iron
Fe2O3 Fe3O4 FeO Fe
2. Calcination of Limestone and Dolomite
CaCO3 CaO + CO2
CaCO3.MgCO3 CaO.MgO + 2CO2

REACTIONS IN MELTER-GASIFIER
1. Creates the reduction gas by gasifying the coal with oxygen and then cooling it.
2. Then, DRI is redirected to the char bed where the iron and slag are melted and
directed to the hearth zone.
During this process, CO and H2 gas exit the gasifier and other by-products are
captured in the metallic slag. The rest of the hot gas is then cooled and sent into
the reduction shaft, known as the Corex export gas, which is used to control the
pressure in plant.

PRODUCT ANALYSIS:
Hot Metal:

Gas:

Slag:

Suvam Das

FASTMET AND FASTMELT PROCESSES OF

I RONMAKI NG

FASTMET process which is a coal based

direct reduction process of iron making.
The FASTMET process converts iron ore
pellet feed, iron ore fines and/or
metallurgical waste from the steel plant
into direct reduced iron (DRI) using
pulverized non coking coal as a reductant.
The end product DRI can be hot briquetted
(HBI), discharged as hot DRI into transfer
containers, or cooled if cold DRI is needed.
FASTMELT process is the FASTMET process
with addition of an Electric Iron Melting
Furnace (EIF) to produce liquid iron or hot
metal.
Saikat Dey & Vartha Kota Sai Dinesh

 Process starts with pelletizing/briquetting of fine

iron ore or pellet feed ore and ground reductant
(non coking coal).
The materials are placed on the RHF in a single
layer.
In FASTMELT, kinematics is normally controlled
by the reduction gas diffusion from the outside.
Once the composite pellets/briquettes are
heated, CO inside them is formed which promote
the reduction of iron oxide.
The atmosphere in EIF of FASTMELT process
consists of CO. This reducing atmosphere
promotes silicon reduction and sulphur removal.
The rapid reduction rate (typical reduction time 6-10 min)
achieved in the FASTMET process is due to the high
reduction temperature, the high heat transfer rate, and the
intimate contact of the carbon contained inside the
briquettes with the iron oxide.
The temperature of the hot metal produced ranges from
1450 deg C to 1550 deg C and it has the following typical
composition: C 3.0 % to 5.0 %, Si 0.3 % to 0.6
%,
Mn 0.6 % to 1.2 %, S <0.05 %, P < 0.03 %

HISMELT : Liquid Iron Smelting

Reduction Process When CO and H2 are released from smelting in the bath,

An innovative air-based direct smelting

technology.
Iron ore fines, coal and fluxes are injected
directly into the melt in the SRV On contact, the
coal breaks up, and the carbon reacts with the
oxides in the iron-bearing feeds and forms
carbon monoxide. The rapid heating of the coal
cracks the coal volatiles, releasing hydrogen. The
rapid expulsion of the carbon
monoxide, hydrogen and nitrogen carrier gas
from the molten iron bath propels a fountain of
molten material, consisting largely of slag, into
the topspace. As this happens, hot air at 1200C
is blasted into the topspace through a watercooled lance. The oxygen content of the hot air
post-combusts with the carbon monoxide and
hydrogen, and the heated metal and slag fall
back into the bath, providing the energy for
direct smelting
Reactions
: of the iron ore.

(Principle & Reactions)

the rate of release is such that a violent eruption of liquid

is produced. Metal and slag are thrown upward forming a
gas-permeable fountain with high surface area for heat
transfer. Hot combustion gases pass through this fountain
and, in doing so, transfer heat to the droplets of slag and
metal which in turn deliver this heat to the bath.
Higher Quality Iron Compared to blast furnace.
Typical Analysis(%):Carbon 4.4 +/- 0.15,Silicon
<0.01,Manganese<0.02,Phosphorus 0.02
+/0.01,Sulphur 0.1+/- 0.05

Temperature:1430 1500 C
Uses metal bath for primary reactions to occur
Single stage process(Reduction & Melting in the same
vessel).
Non shaft type of reactor
CO(+ H2) released from the bath
Reformed natural gas is combustion medium.
used.
provides the fuel for generating
Flexibility in raw materials
3Ciron + Fe2O3 2Feiron + 3CO (highly
this heat
Coal performance has virtually no dependence on
endothermic)
Smelting occurs in the melt where the oxygen potential is particle morphology, since the coal is ground fine for
2CO + O2 2CO2
low, whereas heat generation occurs in the topspace where injection.
2H2 + O2 2H2O
oxygen potential is relatively high. The key to the process Minimized total energy consumption.
is moving heat from the combustion region down to the
Simplified engineering and process configuration
SANDEEP KUSHWAHA smelting region without compromising the oxygen
Environmental emissions well below the industry
potential in either zone.

Raw material selection along with operating parameters (e.g. hot blast
rate and level of oxygen enrichment) can be adjusted to maximize the
efficient use of the process in line with steelmaking requirements. The
ease with which the process can be started, stopped and idled provides
flexibility to the integrated steelmaker that is currently unavailable.

The Hismelt process directly injects iron ore fines (-6mm) (no
sinter, no pellets) and does not require agglomeration. The
process also requires non-coking coal (no coke making), which is
crushed and dried prior to injection into the Smelt Reduction
Vessel (SRV). A wide range of coals that are not suitable for the
Ejected slag coats the water-cooled panels, so reducing energy loss.
blast furnace can be used.
The offgas is cooled via a water-cooled hood and cleaned in a scrubber.
A variety of feed materials can be used in the Hismelt
It can be used as fuel for hot blast stoves and other equipment, such as
process, such as:
a co-generation plant.
Hematite Fine iron ores
Magnetite concentrate
The metal can be mixed directly with blast furnace iron or
Titano-magnetite ore and Iron Sands
alloyed to provide precise low silicon content for the BOF
HISMELT : Liquid Iron
Non-coking coals : Dried and ground to charge. So, compared to a blast furnace hot metal,
Smelting Reduction
3mm,
A wide range of coals can be utilized from
Hismelt hot metal:
Process
semianthracites to high volatile steaming coals
Reduces flux consumption
Steel plant wastes : Fine steel plant wastes
Increases liquid steel yield
(Charging Material &
and
metallic fines - DRI fines, mill-scale, blended
Increases productivity due to a reduced blowing time
Products )
reverts and other iron sources, BOF slag - as a flux
Produces higher quality (low phosphorus) grades
and source of iron units, Coke breeze.
Reduces re-blows reduces refractory consumption
Lower operating costs : Low cost iron making is achieved
Decreases consumption of Ferro-alloys
through the elimination of front-end processes such as coke
Allows production of ultra-clean steel.
ovens and sinter plants
not being operating
The economic performance of the process at relatively low production
commercially
capacities allows the use of multiple units to replace large blast
furnaces. This, coupled with the potential for significant increases in
productivity of each unit through raw material selection, means that
the impacts of downtime and relines can be more easily
SHUBHAM
accommodated.

Iron Ore Deposits in India

The following 4 varieties of Iron ore are generally recognised in
India.
i.
Magnetite -The best quality of iron ore and contains 72 % of
pure Iron. It posses magnetic properties and is dark brown to
blackish in colour. It is found in Jharkhand, Goa, Kerala, M.P,
Tamil Nadu and Karnataka.
ii. Haematite - It contains 60 % to 70 % pure iron and is mainly
found in Andhra Pradesh, Jharkhand, Orissa, Goa, Karnataka,
Maharashtra and Rajasthan. It is reddish or ochre red in
colour.
iii. Limonite Hydrated iron oxide. It contains 40 to 60 % pure
iron. It is of yellow or light brown colour. In India, the deposits
are found in Garhwal ( Uttarakhand ), Kangra valley (
Himachal Pradesh ).
iv. Siderite Carbonate ore of iron. It contains only 40 to 50 % of
pure iron. Due to the presence of lime, it is self fluxing. It is an
inferior variety and is brown in colour. Deposits are mainly
found in Uttarakhand , Himachal Pradesh and Uttar Pradesh.

Deepu Ashok- 13118019

Group-7

State-wise Distribution of Iron Ore Reserves

The total in situ reserves of iron ore in the country are about
12,317.3 million tonnes of hematite and 5395.2 million tonnes of
magnetite.

Karnataka has the largest reserves accounting for about 26 per cent of
the total reserves of India. This is followed by Orissa (25%), Karnataka
(12%), Madhya Pradesh and Goa (17%).

Iron Ore Distribution

It is clear from the left chart that production of iron ore and its value
had been increasing regularly over the years.

Only six states i.e. Jharkhand, Orissa, Madhya

Pradesh, Chhattisgarh, Karnataka and Goa account for over 95 per
cent of the total reserves of India.

Exports to China has increased due to surge in demand. More than

90% of exports comprise of iron ore fines

Praveen Kumar Gupta- 13118062

Group-7

Limestone Deposits
Limestone is a sedimentary rock composed largely of the minerals calcite and
aragonite, which are different crystal forms of calcium carbonate (CaCO3).
Various deposits and production of limestone in India are as follow:
1. Sejahata in Satna district of MP
: 237.58*
2. Redipalayam in Ariyalur district of Tamil Nadu : 232.80*
3. Kota district of Rajasthan
: 236.24*
4. Kovaya in Amreli district of Gujarat
: 157.40*
5. Bastar district of Chhattisgarh
: 136.67*
6.Gulbarga district of Karntanaka
: 121.81*
*- Statistics from google latest in the year (2002-03) and the districts metioned are the
largest producer of limestone in that respective state among all the producers in it.

Ravi Kumar-13118069
Group 7

Various probblems and uses of limestone in industries are:

1. Typical public concerns about limestone mining include dust, noise, blasting
vibration, and truck other traffic associated with quarry operations.
2. When limestone is an aquifer, there can be concerns that contaminants from the
quarrying operations could escape into the groundwater.
3. In cavernous limestone aquifers, contaminants in groundwater move much faster
than in other types of rocks, so quarries in such areas are special concerns.

Uses of limestone in industries:

1. Ground limestone is one of the most important fertilizers.
2. Burnt and hydrated lime are used in many industries to neutralise acid waste.
3. They are used as causticisers in the pulp and paper industry.
4. Limestone is also used as flux in the steel industry.
5. Lime is also used in road stabilisation and gold recovery.
Bharath Gadela -13118029
Group-7

Distribution Of Coal Deposits in India

Coal reserves in India is one of the largest in the world. As on April 1, 2012, India had 293.5 billion metric tons
(323.5 billion short tons) of the resource.
The production of coal was 532.69 million metric tons (587.19 million short tons) in 2010-11. The production
of lignite was 37.73 million metric tons (41.59 million short tons) in 2010-11. As on 2011, India ranked 3rd in world coal
production.
The energy derived from coal in India is about twice that of energy derived from oil, whereas worldwide, energy
derived from coal is about 30% less than energy derived from oil.

Amrutkar Rohan-13121002
Siddhant Tripathy-13410022

Coal category wise, Percentage of coal resource of India

India alone accounts for 10% of the global coal resources at over 101 billion tons (thermal & coking) of proven
reserves, placing her at the third position globally behind the USA and China.
At the current rate of consumption it is estimated that it will take more than 200 years to consume the available coal
reserves.83% of the existing coal reserves in India belong to the Non-coking category (grades E, F, G) which is consumed
mainly for Power, cement and fertiliser production.
India has a total reserve of lignite of 38.76 billion tons, almost 80% of which is found in Neyveli, Tamil Nadu.

Amrutkar Rohan-13121002
Siddhant Tripathy-13410022

REFRACTORY MATERIALS USED IN BLAST FURNACE LINING

A modern blast furnace (BF) is refractory lined to protect the furnace shell from the high
temperatures and abrasive materials inside the furnace.
To achieve the goal of long lining life under stringent operating conditions, it is necessary to
have a good combination of high grade refractories.
The stack bricks are particularly exposed to high abrasion and erosion by charge material from
top as well as high velocity fume and dust particles going out due to high blast pressure in a
CO (carbon mono oxide) environment. Hence, the application condition demands refractory
materials which must have high strength, low permeability, high abrasion resistance and
resistance to CO disintegration. Super duty fireclay refractory brick or dense alumina brick
having Al2O3 around 39 % 42 % can impart these required characteristics.
The tuyere and bosh are attacked by temperature change, abrasion and alkalis; and the belly
and lower shaft by thermal shock, abrasion and CO attack etc.So, silicon carbide, SiCSi3N4 and corundum refractories are used in these zones of blast furnace.
The bottom and a part of hearth are subjected to corrosion by slag,pig iron and alkali and also
to high load and temperature.So, a refractory lining which should have high strength, lower
creep in compression value and higher RUL (refractoriness under load) . Some BFs use low
iron, dense 42 % -62 % alumina, mullite refractory bricks, conventional carbon blocks etc. in the
bottom and lower hearth.
ESHAAN KULSHRESHTHA
13118023 , GROUP-7

DIFFERENT TPYES OF BF REFRACTORIES

BAKED CARBON BLOCKS- Micro porous carbon block, semi graphitic carbon block, and micro porous
carbon silicon block are made with high temperature electrically calcined anthracite, synthetic graphite
and silicon carbide as main raw materials. They possess higher thermal conductivity, lower permeability,
good hot metal and alkali resistance.
CORUNDUM BRICKS- The corundum brick is made of brown fused corundum and silicon carbide as
starting materials, combined with special additives, through mould press process and sintering before
fine machining. It is characterized by good alkaline resistance and slag corrosion resistance which is
suitable for lining the bottom, hearth ceramic cup, tuyere, tap hole and slag hole.
ALUMINA BRICKS- 50 % alumina bricks usually have low porosity, expand upon reheating to 1600 deg C
and have good resistance to thermal cycling, They exhibit good load bearing qualities and have excellent
resistance to alkali attack.60% alumina class bricks exhibit excellent creep resistance. 70 % alumina bricks
exhibit high expansion values in service thus reducing joint sizing.80% alumina class bricks have greater
resistance to abrasion and low porosity.
FIRECLAY BRICKS- They have good refractoriness, resistance to thermal shock and volume stability at
higher temperatures, semi silica firebricks that have typical alumina contents of 18 % to 25% with silica
values ranging 72 % to 80 % and have excellent load bearing strength and volume stability at relatively
higher temperatures.
BHOOPENDRA MEENA
13118015 GROUP-7

Factors Affecting Blast Furnace(Grp-9)

COKE RATE

Coke Rate=Consumption of BF coke in Kg of BF coke consumed per tone of hot

metal produced
Act as major energy source (fuel), reductant, carburizing agent and permeable
structure support
Flux calcination require heat thus increases coke consumption thus efficiency
decreases, thus reduction of 100 kg of flux in burden reduces coke rate by 2035 kg/thm.
Increase in BF temp. by 100 deg C reduces coke rate by 2%.
With every increase in BF top pressure by 0.1 kg/sq cm coke rate decrease by
0.1%. Lower specific volume of slag of lower viscosity improves coke rate.
1 tone of pulverized coke replaces 0.9-1 tone of BF coke thus efficiency
increases and replaces BF coke
High permeability and homogenity of burden across all zones will reduce coke
rate
Abhinav (13118001)
)

Hot Blast
Hot blast refers to the preheating of air blown into a blast furnace or other
metallurgical process.
Large volumes of air, from 80,000 ft3/min to 230,000 ft3/min, are
generated from a turbo blower and flow through the "cold blast main" up
to the stoves to form "hot blast".
The hot blast temperature can be from 1600F to 2300F depending on
the stove design and condition.
The hot blast is directed into the furnace through nozzles called "tuyeres".
These tuyeres are equally spaced around the circumference of the
furnace. There number may vary from 14 to 40.
The hot air that is blown into the bottom of the furnace ascends to the top
in 6 to 8 seconds after going through numerous chemical reactions.
A consistently high temperature of the blast gas is critical for the efficient
operation of the blast furnace.
Rahul (13118066)

HIGH TOP PRESSURE

HTP is maintained by control
mechanism on the
offtake(escaping gases) of the BF
It contain scrubber (cooling and
cleaning of top gas) and cause
substantial drop in pressure of
gas.
It lead to 2 plants
-Dry gas cleaning plant=retain
sensible heat for heat recovery
-Top Gas Recovery Turbine=to use
pressure to generate power
1.
2.

3.

BF off gas cleaning is done by dust catcher or cyclone in

conjunction with an annular gap wet scrubber.
Movable cone assembly control the top pressure. It
reduces fuel rate by decreasing velocity of the gases
and by increasing retention time for the gas-solid
reactions.
Also reduce the hot metal silicon variability and
increases productivity

Thus lead to less power

consumption and efficiency
increase
Shivam
(13118086)

BURDEN MATERIAL
Lumpy iron ore(10-40mm), in the form of hematite or magnetite or iron
oxide in the form of pellets and sinters, flux and metallurgical coke
constitute the burden materials in BF.
The average ratio of ore:flux:coke is 7:1:3 for US ores.
For achieving higher productivity, it is essential that burden material
provides high permeability and homogeneity across all furnace
temperature and reaction zones. So burden material should be porous.
Lower thickness of coke and iron ore layers help in increasing reactivity
and hence, effectiveness of BF . Composite agglomerate (RCA) and ferrocoke offer highest reactivity .
20% lumps and 80% sinter/pellets are generally used. Pellets are
expensive in comparison to sinter and are used accordingly.
The limestone is the most popular flux in blast furnace and sintering
process. The limestone charged in the blast furnace must be in lumps (2560 mm across).
Favas(13118024)

Blast Furnace Design

Blast furnace is conical in shape with a thicker girth at the bottom area to
accommodate a larger volume inside the bosh and belly as the hot gases are
released in this area.
The BF design is based on the concept of free standing unit with a surrounding
building structure providing access to the furnace and gas system or
supported ring system in which a lintel supports the whole furnace.
The blast furnace is 26-36 mts in height. Diameter range is 10-15 metres.
The size of various components of BF belly(2-3m)<throat(2.5-3m)<bosh(34m)<hearth(3.2-5.7m)<stack(15-21m).
The outer shell is lined with various types of refractory materials to limit the
temp rise of the furnace itself.
Some of them are fireclay bricks ,carbon bricks (used for protecting bottom of
crucible).They have basic nature.
There are tuyers below the belly for blowing hot air blast.They are generally
12-42 in number depending upon size of furnace.
Anshuman (13120007)

ROLE OF INJECTANTS IN BLAST

FURNACE
Injection of hydrocarbon liquids , gases or solids through the tuyeres
has led to improve furnace productivities by lowering the requirement
for coke in the solid charge. Oil, tar, natural gas, powdered coal and
oxygen can be injected into the furnace at tuyere level to combine with the
coke to release additional energy
This leaves more space in the stack for ore and it leads to a greater
reduction capacity.

The price of coke has been high relative to the prices of fuel oil
and natural gas per unit of reducing capability or enthalpy and
injection of these fuels through the tuyeres has resulted in direct
cost savings .
However , recent increases in the prices of natural gas and fuel oil
have reduced this direct cost saving.
.
Shailja (13118082)

Pulverized coal injection method

Pulverized Coal Injection (PCI) is a process that involves blowing large
volumes of fine coal granules into the BF.
This provides a supplemental carbon source to speed up the production of
metallic iron, reducing the need for coke production. As a result energy
use and emissions can be reduced.
However, as coke provides physical support and gas permeability in the
BF, its complete substitutions is not possible
The amount of coal that can be injected will depend on the coal and coke
quality, furnace geometry, and operational practices.
The PCI method is based on the simple concept of primary air (termed the
"conveying gas") carrying pulverized coal which injected through a lance to
the tuyere, then mixed with secondary hot air(blast), which then creates a
raceaway in furnace.
The use of coal blend (mixing different coals) injection methods are
attracting industry.
Aviral (13118013)

REDUCING GAS
Besides CO and carbon, hydrogen can also be an equivalent deoxidizing
agent, although often combined with CO.
The use of high-reactivity coke can decrease the reducing agent rate
(RAR).
The mechanisms by which the use of high-reactivity coke improves the
efficiency of furnace inner reactions include :
(1) control of the FeO-Fe reduction equilibrium point, or lowering of the
thermal reserve zone temperature,
(2) higher reduction ability of gas due to higher reactivity of coke
(3) accelerated ore reduction by gas due to :
(i) the reduction of FeO into Fe at lower temperatures
(ii) an increase in the volume of fine pores in ore grains
Coal is a large source of hydrogen. Thus CO along with hydrogen improves
the reducibility of iron ore.
Increasing the percentage of reducing gas increases the efficiency of blast
furnace.
Pratyush (13118061)

Method employed to extract a metal by a reduction process largely depends on its reactivity.

Iron is less reactive than carbon, so carbon can replace it from iron oxide (hematite - iron ore)
and would be easily extracted using carbon based smelting. Also, Smelting(heating with carbon)
is a lower energy process, a lot cheaper that electrolysis.

Electrolysis makes use of electricity, hence becomes very expensive process. A large amount of
electricity is required in electrolysis of iron(about 2000 kilowatt hours per tonne of iron
produced.)

Iron doesnt have great affinity towards oxygen while metals higher in reactivity series have high
affinity so their electrolysis is easier.
Iron is not usually obtained via electrolysis because it also leads to corrosion. E.g. If you subject a
water soluble salt FeCl3 to electrolysis, Fe3+ ions would migrate to the cathode, pick up 3
electrons and deposit there as iron metal which will corrode this solution.
-Kumar Vibham(13118037) &
Prithavi Chand (13118063)

Electrolysis is easier for ionic compounds which is not the case in compounds of iron

A new way of Extraction of Iron via Electrolysis

Producing iron by electrolysis rather than conventional smelting could prevent the emission
of a billion tonnes of carbon dioxide into the atmosphere every year.
So concludes Donald Sadoway, a materials scientist at MIT in the US who has developed a way
producing iron by electrolysing a molten iron oxide in the lab. If the process can be scaled
up, it could eliminate the need for conventional smelting, which releases almost a tonne of
CO2 for every tonne of steel produced.
In conventional smelting, iron ore is combined with a coal-derived carbon called coke. The
coke reacts with the iron, producing CO2 and carbon monoxide, leaving pure iron behind.
Electrolysis produces iron a different way. The iron ore is dissolved in a solvent of silicon
dioxide and calcium oxide at 1600C and an electric current passed through it. Negativelycharged oxygen ions migrate to the positively charged anode, and the oxygen bubbles off.
Positively-charged iron ions migrate to the negatively-charged cathode where they are reduced
to elemental iron which collects in a pool at the bottom of the cell and is siphoned off.
However the technology has a number of hurdles to overcome.

-Kumar Vibham(13118037)&
Prithavi Chand (13118063)

Physical separation : By mineral beneficiation (physical separation) we can

eliminate some particles that contains impurities, which includes alumina and
silica.
By adding flux in the blast furnace : we add flux (limestone CaCO3) in the blast
furnace which on decomposition at above 800C forms CaO (basic in nature).
It combines with acidic impurities mainly Alumina and silica at high temperatures
and forms molten slag.
In this process following reactions take place :
decomposition of limestone above 800C CaC03 ==CaO+CO2
This is an endothermic reaction.
After the formation of CaO, alumina and silica will react with this to form slag.
CaO + SiO2 == CaSiO3 ( calcium silicate )
In the similar way alumina also forms 3CaOAl2O3 (calcium aluminate)
We prefer this method because alumina and silica have very high melting point
but slag has relatively lower melting point and there is adequate difference in
specific gravities of slag and hot metal. We can separate molten metal from slag
via tapholes.

 In

case of DRI there is no melting process, simply removal of

oxygen from solid iron ore is taking place in the rotary kiln and
produce sponge iron.
So, whatever impurities present in the iron ore initially remain in
the DRI.
Gangue materials in the DRI needs to be separated via slag in
the Electric arc furnace ( EAF ).
By: Sushant kumar and Prateek goyal

Q3. Difference between Pig iron and Sponge iron

Pig iron

Sponge iron

Pig iron has a iron content of 9095% and high carbon content (5%
and more)
Non porous in nature.
Comparatively high sulphur and
phosphorus content.
Pig iron is produced by melting iron
ore under high pressure with
charcoal and limestone.
This has high carbon content and is
brittle and unstable.
The carbon dissolves in the
iron, reducing its melting point so
that it can be poured and
solidified as high-carbon ingots.

It has high iron content (80-85%)

and high degree of metallization.
It has porous nature.
It contains lower sulphur and
phosphorus content
Sponge iron is Direct Reduced
Iron". The iron ore is heated with a
reducing gas, which reduces it to a
sponge of solid iron.
This has comparatively low carbon
content and less brittle.
Sponge iron is used in electric
furnaces. It can also be mixed with
different metals.

Made by: Mahaveer Kumawat

Wrought iron

Cast iron

It is the purest form of iron.

It is manufactured from cast iron by pudding

process

It contains the lowest percentage of

carbon less than .08 percent.

It contains 0.35% other impurities.

Wrought iron is extremely toughed, highly

malleable and ductile , resistant to
corrosion.

Wrought iron has been worked with tools.

Smelted at a relatively low temperature in
the solid state

It is the most impure form of iron.

Cast iron is the material produced
by re-melting pig iron.
It contains the highest percentage
of carbon from 2.1to 4 percent.
It also contains about 2 percent of
other impurities like Si, P, Mn and S.
Due to high carbon content, it is
hard and brittle and cannot be
welded.
Cast iron has been put in a mould.

Smelted at much higher temperatures

in the liquid state

Ankit baswal

1. ROCK DEF-Rock is a naturally occurring solid aggregate of one or more minerals which does not have a
specific chemical composition.
PURITY- contains many types of minerals so it is not pure.
STRUCTURE-sedimentary iron rocks have structures like cross bedding, graded bedding and ripple marks
PROPERTIES-porosity, coloured, lustre, texture, shape and pattern.
2. MINERAL DEF-A mineral is a naturally occurring substance that is solid and inorganic representable by a
chemical formula and has an ordered atomic structure.
PURITY- In nature, minerals are not pure substances, and are contaminated by whatever other elements are
present in the given chemical system
STRUCTURE- Minerals are typically described by their symmetry because of the geometric spatial
arrangement of atoms in their internal structure. Minerals are composed of the same substance throughout
the sample.
eg. hexagonal, tricinic, monoclinic etc..
PROPERTIES-1.hardness-controlled by the chemical composition and crystalline structure of a mineral.
2. Lustre-Metallic and sub-metallic minerals have high reflectivity like metal.
3.Color- caused by electromagnetic radiation interacting with electrons
4.Transparency
5- Streak

3. ORE

DEF-An ore is a type of rock that contains sufficient minerals with important elements including metals

that can be economically extracted from the rock.

PURITY- ores contain a large amount of value metal so they can directly be used for extraction purposes but
also contains some gangue or unwanted materials.

STRUCTURE- crystal structures of different iron ores are cubic, rhombohedral, orthorhombic.

PROPERTIES-reducibility, metallization, swelling, load bearability, easy disintigeration, solubility.

4. CONCENTRATE

DEF-The desired mineral that is left after impurities have been removed from mined ore

PURITY- metal content is more than pure ore as concentrate is obtained after beneficiation.

STRUCTURE- concentrate structures just like ore structures are cubic, rhombohedral, orthorhombic.

PROPERTIES-reductibility, load bearability, permeability, porosity, specific gravity, pellet formation.

5. TAILING METAL

DEF-The materials left over after the process of separating the valuable fraction from the uneconomic fraction
(gangue) of an ore. They are byproducts left over from mining .
PURITY- tailings consist of a slurry of fine particles, ranging from the size of a grain of sand to a few micrometres
which is a mixture of fine mineral particles and water.
STRUCTURE- They are stored in tailing ponds. the grain size varies from 0,01 mm to 1,0 mm, but up to 20 % claysized particles, i.e. 0,002 mm
PROPERTIES- Tailings generally have high water content and porosity, a low to moderate hydraulic conductivity
and a low plasticity when compared to soil.

VASANTH BALAKRISHNAN
VIJAY KUMAR VERMA
SUKHBIR
DEEPESH YADAV
MONTY BANSAL
PARVESH
PINAPALA SAI TARUN
SUSHMITA NANAWATI

(13121029)
(13120023)
(11118091)
(13118018)
(13118044)
(13118055)
(13118056)
(13118095)

UNDER GUIDANCE OF
DR.NIKHIL DHAWAN, ASSISTANT PROFESSOR IIT ROORKEE
DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING

Reduction:
Fe2O3 + 3CO 2Fe + 3CO2
Fe2O3 + 3H2 2Fe + 3H2O
Carburization:
3Fe+CO+H2->Fe3C+H20
3Fe+CH4->Fe3C+2H2
Reforming:
CH4 + CO2 2CO + 2H2
CH4 + H2O CO + 3H2
PARVESH 13118055

 The principle involved in the MIDREX process is the countercurrent flow of the reducing gas
and the charge material.
The charge material is fed into the furnace from the top through seal legs and the reducing
gas enters the furnace from the bottom of the reducing zone.
CHARGING MATERIALS in MIDREX process:
Iron Ore(Lumps and Pellets-40% and 60%) , non-coking coal and Natural gas
Natural gas is used for providing combustion medium and reducing gas(CO & H2)
PRODUCTS:
Sponge Iron-DRI(Metallic Iron-83 to 86%, C-1.2to 2.5%,Oxide-5 to 8%,S-0.05 to 0.025%,P0.03 to 0.08%,Residuals-0.02 to 0.05%)
Top gas - CO2 and H2O is released at the top of the furnace.

PINAPALA SAI TARUN 13118056

Reactions:H2 As Gas
3Fe2O3 + H2 = 2Fe3O4 + H2O
Fe3O4+H2=3FeO+H2O
FeO + H2 = Fe + H2O

CO As Gas
3Fe2O3 + CO = 2Fe3O4 + CO2
Fe3O4 + CO = 3FeO + CO2
FeO + CO = Fe + CO2

VASANTH (13121029) AND MONTY (13118044)

Principle:- The HYL process in principle is not much different from MIDREX process. The main
difference is that ore is maintained in a stationary position in 4-5 of fixed beds and gas is made to
flow from one bed to another. Natural gas is converted to a mixture of CO and H2 which at a
temperature of 900- 1000 deg is passed through a bed which contains partially reduced ore, which
is reduced to metallized state. The gas from this bed is cooled to condense most of its vapour and
reheated and introduced in a bed which has less reduced ore. Operation is repeated for third bed
containing fresh hematite which is heated to reaction temperature and prereduced. Remaining
beds are charged with fresh ore or being cooled by cooling gas and metallized product is removed.
Also reaction may be carried out at increased pressure with correspondingly higher reaction rate.
Charge Material for HYL Process:Charge material is iron ore pellets and lump ore(10 to 30 mm) along with natural gas (natural
gas based HYL) or gasified non coking thermal coal( coal based HYL) at a temperature
profile ranging from 800-1050 deg C.
High methane containing natural gas is the most commonly used gas.
As the process includes a sulfur removal step, it can utilize higher-sulfur ore and gas feeds.
Products of HYL:Product obtained is high quality DRI( hot or cold) having 90-91% Fe and approx. 1.5-2.5%
Carbon, 3.5-4 % gangue impurities. It can also produce HBI( Hot Briquetted Iron).
Slag is not obtained in this process.
Hot DRI can be directly fed into EAF reducing costs of production.

VASANTH (13121029) AND MONTY (13118044)

Gas based DRI

Inputs: Iron ore ( 85% Fe2O3 + 15% SiO2)
Natural gas ( 60%C)
Flux ( dolomite pure CaMg(CO3)2 )
Reaction : 2Fe2O3 + 3C
4Fe + 3CO2

Output: DRI - 1 tonne

( 93.5%Fe + 1.85%C+
4%Gangue + 1.5%Flux)

1.Fe balance:
0.85 * ( 112 ) * x /160= 0.935 * 1
mass of ore, x = 1.57 tonnes
2.Flux used = 0.015 * 1 = 0.015 tonne = 15 kg
3.Carbon balance: y * 0.60 + 0.015 * ( 24 )/184 = 0.0185 * 1 + 0.935 * 1 * ( 12*3 )/(56*4)
mass of natural gas , y = 0.278 tonne = 278 kg
4.Slag = Flux + Gangue
= ( 0.015 + 0.04 ) * 1 = 0.055 tonne
mass of slag = 55 kg
Vijay Kumar Verma 13120023

Coal based DRI

Inputs: Iron ore ( 85% Fe2O3 + 15% SiO2)
Coal ( 35%C + other materials)
Flux ( dolomite pure CaMg(CO3)2 )
Reaction : 2Fe2O3 + 3C

Output: DRI - 1 tonne

( 92%Fe + 0.23%C+
3.5%Gangue + 3%Flux)

4Fe + 3CO2

1.Fe balance:0.85 * ( 112 ) * x /160 = 0.92 * 1

mass of ore, x = 1.546 tonnes
2.Flux used = 0.03 * 1 = 0.03 tonne = 30 kg
3.Carbon balance: y * 0.35 + 0.03 * ( 24 )/184 = 0.0023 * 1 + 0.92 * 1 * ( 12*3 )/( 56*4)
mass of coal , y = 0.418 tonne = 418 kg
4.Slag = Flux + Gangue
= ( 0.003 + 0.035 ) * 1 = 0.065 tonne
mass of slag = 65 kg
Sushmita Nanawati 13118095

Properties and uses of sponge iron

Sponge iron properties:
Density of sponge iron is 3.5 to 4.0 g/cm3 due to this density value sponge iron have the ability to penetrate in to
the slag layer and reside at the slag/metal interface for effective heat transfer and chemical reaction.

During continuous feeding, an active carbon oxygen boil is necessary to shield the arcs. It has been observed that to
achieve the aforesaid, sponge iron should possess a minimum of 0.6 % carbon.

It picks up little carbon during process.

High iron content, high degree of metallization and Highly reactive with moisture.

Uniform and consistent quality

Lower sulphur and phosphorus content and Negligible tramp element

Minimum dust generation during material handling

Good flowability in bins, pipes and conveyors for continuous and trouble free charging

Superior technical support to induction furnace operators

Uses:
Sponge Iron is one of the most important and the basic raw materials required for the production of various steel/iron
based products like TMT bars, D.I Pipes etc.

Sponge Iron is a partsubstitute for steel scrap used for manufacturing steel by electrical arc furnaces and induction
furnaces.

Steel melting scrap is primarily required for using as a feed material in all mini steel plant that use this scrap for
melting in electric arc furnace/induction furnace to manufacture steel.

Sponge Iron is also good suitable material for using as a coolant in LD converters of the Integrated Steel Plants.

Sponge iron is created by reducing iron ore without melting it. This makes for an energy-efficient feedstock for
specialty steel manufacturers which used to rely upon scrap metal.

One of the more common uses for sponge iron is the creation of wrought iron. DEEPESH YADAV

Sponge Iron/Direct Reduced Iron (metallization and composition)-: It is the resulting product (with a metallization degree
greater than 82 percent) of solid state reduction of iron ores or agglomerates (generally of high grade), the principal
constituents of which are Metallic iron, residual iron oxides carbon' and impurities such as phosphorus, sulphur and gangue
(principally silica and alumina).

Sponge iron shall be classified into three grades based on the percentage of total/metallic iron content, the level of
impurities gangue and sulphur/phosphrous. Sponge Iron/DRI (lumps) and HBI - The chemical composition of sponge iron /DRI
and HBI shall conform to the requirements given in Table . Sponge Iron/DRI (lumps) and HBI - The chemical composition of
sponge iron /DRI and HBI shall conform to the requirements given in Table
Chemical Composition of Sponge Iron (Chemical Analysis in Percentage)

Metallization -: It is a measure of the conversion of iron oxides into metallic iron (either free, or in combination with carbon
as cementite) by removal of oxygen due to the action of the reductant used.
Degree of Metallization -: It is used to describe the extent of conversion of iron oxide into metallic iron during reduction. It
is defined as follows:
Mass of metallic iron
Degree of metallization (percent) = ------------------------ X 100
Mass of total iron
Equivalent Metallization -: Carbon content in sponge iron at a given degree of metallization is important it has the capacity
to remove oxygen from the remaining iron oxides during steel making. This leads to the concept of equivalent metallization,
which may be defined as:
Equivalent Metallization (percent) = Degree of metallization (percent)+ 5 times
the Percent of total carbon in sponge iron
SUKHBIR 11118091

Sintering
Sintering is a heat
treatment applied
to a powder
compact in order
to impart strength

Manoj Patidar: 13118040 (Group 13)

Abhishek Meena: 13118004(Group 13)
Sintering enhances properties such as
strength, electrical conductivity, translucency
and thermal conductivity

Sintering is effective when

process reduces porosity
Temperature
used is below
the melting
point of major
constituent of
material
The concentrate is placed on the pallet , below the ignition hood. The wind box is a
suction box. Therefore, a thin layer of product is formed which moves on pallet. The
wind boxes blows air which carry heat with it. Thus, agglomerate of roast are formed
which are discharged. The discharge obtained is called Sinter.
Dwight Lloyd Sintering Machine used for Non-Ferrous metals like Zn , Pb

 Sinter size is around 10-12mm

Advantages
Very high levels of purity and uniformity in starting materials
After sintering the mechanical strength to handling becomes

higher.
Capability to produce nearly net-shaped objects.
Capability to produce materials of controlled, uniform porosity.
Capability to produce materials which cannot be produced by any
other technology.
No deformation needed to produce directional elongation of
grains.

Disadvantages
100% sintered (iron ore) can not be charged in the blast furnace.
By sintering one cannot create uniform sizes.

PELLETIZATION
MECHANISM
Pelletizing is a process that
involves mixing very finely
ground particles of iron ore
fines of size less than 200 mesh
with additives like bentonite and
then shaping them into
oval/spherical lumps of 8-16 mm
in diameter by a pelletizer and
hardening the balls by firing
with a fuel. It is the process of
converting iron ore fines into
Uniformed Sized Iron Ore
Pellets that can be charged
directly into a blast furnace or

Made by : Saurabh Singh Ujjain

Enrollment no. : 13118079 (group 13)

ADVANTAGES OF PELLETS

Iron ore pellet is a kind of agglomerated fines which has better tumbling
index when compared with the iron ore and it can be used as a substitute for
the same both in the blast furnace and for DR production.

Pellets have good reducibility since they have high porosity (25-30%).
Normally pellets are reduced considerably faster than sinter as well as iron
ore lumps. High porosity also helps in better metallization in DRI production.

Pellets have a uniform size range generally within a range of 8 -16 mm.

Pellets have spherical shape and open pores which give them good bed
permeability.

Pellets have low angle of repose which is a drawback for pellet since it creates
uneven binder distribution.

The chemical analysis is uniform since it gets controlled during the

beneficiation process. Fe content varying from 63% to 68% depending on the
Fe content of Ore fines. Absence of LOI is another advantage of the pellets.

Pellets have high and uniform mechanical strength and can be transported to
long distances without generation of fines. Further it has got resistance to
disintegration. High mechanical and uniform strength of pellets is even under
thermal stress in reducing atmosphere.

:PRABHAV SINGH 13120016 (GROUP 13)

Briquetting involves compaction of fines by application of pressure often at an

elevated temperature. The resultant product has very high density (>5000Kg/m3).
Briquettes are largely used as a feedstock in Alternate Iron Making processes as Hot
Briquetted Iron(HBI) which is the premium form of DRI (Directly Reduced Iron)
and is used in EAF, BOF as well as Blast Furnace.
Manufacturing process involves the following steps

Forming a mixture of crushed fine ore and binders.

Pressing to form a green briquette using a low roll pressure.

Indurating the green briquettes to form a fired briquette.

HBI is formed by compacting DRI under high pressure at temperature of 650C

The following flowchart schematically shows briquette manufacturing process
Mechanism
The low pressure causes compaction by reducing
the spaces between particles. The particles then
are themselves compressed and deformed,

Srijan Sen(13118092,Group-13)

and a molecular bond is created between the particles. High pressures at the end of the
process cause a transition from elastic deformation of the particles to
plastic deformation, which strengthens the briquette and enables it to
retain a given shape. The physical and chemical properties of the raw material are a
major factor affecting the nature of the deformations.

Animation - https://youtu.be/L7JIOwaJZ74
Advantages

Disadvantages

Harshal Kavishwar (13118030) , Group -13

Comparison Between Sintering

,Pelletization and Briquetting

In the blast furnace , we uses the particles of ores of moderate

size .
So we have to agglomerate the fines into particles of sufficient
size .
For the purpose of agglomeration we uses the above
techniques.
Sintering :
1 Size is the range of 20-25 mm.
2 Dwight Lloyd sintering machine is used for the production of
sinters.
3 Sinters are cost efficient i.e. Cheaper in cost to produce.
4 Sinters are weaker in strength.
5 Shape of sinters are irregular.
6 Sinters have lower thermal efficiency.
Ravi Kumar (13118070) (Group 13)

Pelletization:
1

Size of pellets is in the range of 8-16 mm.

2 Two types of systems are used for the pellets production
mainly one is grate kiln system and other is straight grate
system.
3 Porosity of pellets is much better than sinters.
4 Process cost is higher as compared to sinters but cheaper
than briquetting.
5 Green balls are formed in the pelletization which have
higher strength than sinters.
Briquetting :
1 This process is much costly among all the three processes.
2 The typical volume of industrially manufactured briquettes is
in the range of approximately 100 cubic centimetres.
3
In this process binder is not always necessary.
4
Briquettes have limited application in the blast furnace
Shivam Dandotiya (13118085) ( Group 13)

MTN-303 Iron making and Steel Making

Tutorial-1 Hints
1. How does the blast furnace get its name: Due to blast air supply
2. What is the ore: coke: limestone ratio used in iron making? Covered in class
3. Why magnetite ores cannot be used directly for iron making?
Magnetite ores have mere 15-40% iron content and as such, has to be beneficiated to
concentrate the iron bearing material. A lot of Power is used up in the beneficiation
process of magnetite, representing the bulk of the costing.
4. Why do we need to grind iron ore to micron size and later agglomerate for blast
furnace? Liberation issue
5. Wstite (FeO) and iron pyrite (FeS 2 ) are two additional mineral sources of iron. Why
still they are not used in the iron making?
(1) scarcity in the case of wstite; and (2) being used in other processes, such as the
production of sulfur dioxide and iron(II) sulfate from iron pyrite.
6. What are the main impurities in iron ores? What are their safe levels in ores and ill
effects?
Silica
Smelting high silicon ores results in formation of gray iron. Grey iron is brittle but
easier to get a good finish. There is less shrinkage, which is why it was once preferred
for castings. Most silica is slagged off during smelting but at higher temperatures
can be reduced to the point at which it may become incorporated (alloyed) into the
iron. Silica levels in an ore should ideally be <3.5%, but for high grade ores may be
less than 2%. High silica ores can still be used but will probably be blended with high
grade ores to reduce the overall impurity level. Too high and an ore needs to
beneficiated.
Phosphorous
Phohorous is one of the nasty impurities in iron ore. It results in brittle iron. Only low
levels of phosphorous are tolerated. If you have more than 0.01% then the price paid
for the ores is reduced as the ore will require blending with a low phosphorous ore to
reach a tolerable grade. It is not easy to remove phosphorous so it is preferable that
ores are low in phosphorous to start.
Aluminium / alumina
Alumina is another common impurity in iron ores. This reflects its abundance in many
other minerals which might also be included with the iron ore minerals. Alumina is
harder to reduce than silica and is not so easily alloyed into the smelted product.
However, its presence increases the viscosity (or thickness of the flow) of a slag
formed during the smelting process. This viscous liquid waste is harder to remove and
slows down the overall smelting process.
Sulphur
Like phosphorous, sulphur is an impurity to avoid in iron ores. High sulphur ores
(>0.01-0.03%) are to be avoided as it ultimately makes iron brittle, prone to cracking
and failure. Sulphur fumes from smelting are also a source of sulphur dioxide which
can interact with moisture in the atmosphere to produce sulphuric acid.

7. How Ellingham diagram is useful in iron making? Reductant choice/selection

8. Which is Indias largest blast furnace? Comment on its size and processing route.
Covered in class
9. Why India is importing coke for blast furnace? High ash content
10. Which is better for blast furnace: sinter or pellets? Why?
Pellets mostly, but needs comminution extensively