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COMPARISON OF BLAST FURNACE PARAMETERS DURING DIFFERENT SINTER PERCENTAGES

A PROJECT SUBMITTED BY C.SIVA (080114801045), V.VIGNESH (08011480105 ), J.VINOTH (080114801058).

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COMPARISON OF BLAST FURNACE PARAMETERS DURING DIFFERENT SINTER PERCENTAGES

A PROJECT SUBMITTED BY C.SIVA (080114801045), V.VIGNESH (08011480105 ), J.VINOTH (080114801058).

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UNDER GUIDANCE OF

MR. SUDHARSAN SENIOR MANAGER (BF OPERATION) JS1, SALEM 1OR2S.


2

AC2NO1LEDGEMENT

The success of any project work depends upon team work and cooperat on of many peop!e" #e wou!d ! ke to take th s opportun ty to e$press our %rat tude to the peop!e who supported and %u ded us n th s project"

#e

wou!d

! ke

to

e$press

our

deep

sense

of

%rat tude

to

P'&(.P.M.2AVIMANI, M.E., &r nc pa!' Go(ernment Co!!e%e of En% neer n%' )a!em' for h s encoura%ement n th s project work"

#e

shou!d

! ke

to

e$press

our

mmense

%rat tude

to

D'.P.G.VEN2ATA2RISHNAN, M.E., *ead of the Department' Department of +eta!!ur% ca! En% neer n% for h s earnest %u dance and n(a!ua,!e su%%est ons"

#e w sh to e$tend our %rat tude to our %u de M'.SUDHARSAN, )r +ana%er -.F Operat on/ 0)#' for h s de$terous esteemed %u dance' pers stent encoura%ement and do n(o!(ement n fru tfu! d scuss on throu%h our project work"

#e are a!so (ery thankfu! to our facu!ty mem,ers and non1teach n% staff mem,ers for % ( n% us the t me!y su%%est ons and necessary he!p"

T!3%$ &( C&),$),4


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5

1. ABSTRACT=
) nce the ncept on of ,!ast furnace method of ron mak n%' techno!o%y tse!f has e ther under%one a rap d chan%e or has nno(ated techn :ues w th su ta,!e a!terat on and mod f cat on" The pr nc p!e rema n n% the same' the chan%es a m at !ower n% ener%y consumpt on and ach e( n% h %her product ( ty" The ncreased use of s nters as ron ,urden n most ,!ast furnaces s a true po nter to th s c!a m" *owe(er' the pre1e(a!uat on of th s ,urden for ts su ta, ! ty as ,!ast furnace feed s of d re need" 0 nda! )outh #est-0)#/ )tee! #orks has two ,!ast furnaces and they ha(e a tar%et of ncreas n% product ( ty w th decrease n fue! rate' ,!ast rate and ron ore consumpt on rate w th respect to ncrease n = s nter" 0)# has taken the cha!!en%e to fu!f !! th s re:u rement" The present paper dea!s w th the (ar ous factors wh ch contr ,ute towards econom ca! prof t ( a ncreas n% =s nter" )trate% es are a!so descr ,ed n the paper"

7. INTRODUCTION=
The performance of a ,!ast furnace s %enera!!y e(a!uated ,y the !e(e! of ts product ( ty' fue! rate and the :ua! ty of the hot meta!" Usa%e of s nter n ,!ast furnace !ead to the decrease of fue! rate and ,!ast w th ncrease n product ( ty" )o t s essent a! to ncrease the percenta%e of s nter n ,!ast furnace from econom ca! po nt of ( ew" 0)# )a!em )tee! #orks concentrates on t and t has taken e(ery step to ncrease s nter consumpt on" Our project dea!s w th the parameters wh ch %et affected ,y ncrease n percenta%e of s nter"

7.1. JS1 STEEL L,8=


0)# )tee! s an Inte%rated )tee! &!ant owned ,y the 0)# Group ,ased n +um,a ' +aharashtra" The Group set up ts f rst stee! p!ant n 3>?2 at @as nd near +um,a " )oon after' t ac:u red & rama! )tee! 4td"' wh ch operated a m n stee! m !! at Tarapur n +aharashtra" The 0 nda!s' who had w de e$per ence n the stee! ndustry' renamed t as 0 nda! Iron and )tee! Co" 4td" -0I)CO/" In 3>>6' n order to ach e(e the ( s on of mo( n% up the (a!ue cha n and ,u !d n% a stron%' res ! ent company' 0 nda! @ jayana%ar )tee! 4td" -0@)4/ was setup' w th ts p!ant !ocated at Torana%a!!u n the .e!!ary1*ospet area of Aarnataka' the heart of the h %h1%rade ron ore ,e!t and spread o(er 5';BB acres of !and" It s just 56B kms from .an%a!ore' and s we!! connected w th ,oth the Goa and Chenna ports" In 2BB7' 0I)CO and 0@)4 mer%ed to form 0)# )tee! 4td" In the year 2BB6' )I)CO4 wh ch was under 4+# %roup was ac:u red and was mer%ed w th 0)# Group" 0)# )tee! s amon% Ind aCs !ar%est stee! producers' w th a capac ty of ;"? +T as on 2B3B" 0)# )tee! s one of the !ow cost stee! producers n the wor!d" 0)# )tee! offers the ent re %amut of stee! products D *ot Ro!!ed' Co!d Ro!!ed' Ga!(an <ed' Ga!(a!ume' &re1pa nted Ga!(an sed' &re1pa nted Ga!(a!ume' T+T Re,ars' # re Rods E )pec a! )tee! .ars' Rounds E .!ooms" 0)# )tee! has manufactur n% fac ! t es at Torana%a!!u n Aarnataka' @as nd E Tarapur n +aharashtra and )a!em n Tam ! Nadu" .y 2B2B' the Company a ms to produce 56 m !! on tons of stee! annua!!y w th Greenf e!d nte%rated stee! p!ants com n% up n #est .en%a! and 0harkhand" 0)# )tee! 4 m ted has the !ar%est %a!(an < n% and co!our coat n% product on capac ty n the country and s the !ar%est e$porter of %a!(an <ed products w th presence n o(er ;6 countr es across f (e cont nents"
7

9. SALEM 1OR2S
0)# %roup ac:u red the Company and took o(er the +ana%ement from No(em,er 2BB6" )a!em #orks s the on!y nte%rated stee! p!ant n Tam ! Nadu and s !ocated at &ottaner F+" Aa! patt ( !!a%es and at a,out 57 kms from )a!em" As part of the 0)# %roup' the p!ant underwent a dramat c transformat on and started mak n% prof ts from the f rst year onwards" Today' t has ,ecome the f rst 3 +T&A nte%rated stee! p!ant n Tam ! Nadu" It s a!so the h %hest A!!oy )tee! +aker n the Country" The Company s ha( n% fac ! t es for product on of & % Iron' )tee!' . !!et and Ro!!ed )tee! products n the !on% product cate%ory" The present capac ty s ,e n% e$panded to one m !! on tones per annum" It has adopted the ) nter p!ant D .!ast furnace D Ener%y Opt m < n% Furnace D 4ad!e Furnace' @acuum De%ass n% Cont nuous Cast n% +ach ne D ,ar and rod m !! route w th ron ore as the ,as c nput mater a!" It a!so has p!ants for %enerat on of power and product on of o$y%en" )a!em #orks s h %h!y en( ronment consc ous and the process and techno!o%y s des %ned for reus n% and recyc! n% the process waste" #e ha(e an e$pand n% %reen ,e!t to pro( de a %reen en( ronment" &roducts of )a!em #orks ha(e the ha!!mark of :ua! ty and com, ned w th compet t (e pr c n%' they are h %h!y preferred n automo, !e and construct on sectors"

9.1. PLANT DETAILS=


CO2E OVEN= 0)# )tee! 4 m ted' )a!em #orks has one coke o(en of capac ty B"7 +T&A under the techno!o%y of +ECC' Ch na" Th s coke o(en supp! es enou%h coke for the re:u rement of th s p!ant" IRON COMPLE> ??SINTER PLANT= 0)# )tee! 4 m ted' )a!em #orks has two ) nter &!ants 3 and 2" The ) nter &!ant 3 s of 2B m 2 %rate area' supp! ed ,y +Fs 4ur% Ind a Company 4 m ted" The capac ty of the p!ant s B"2 +T&A" The ) nter &!ant 2 s of >B m 2 %rate area" " The capac ty of the p!ant s 3"3 +T&A" ) nter s an nput mater a! for .!ast Furnace and s part a!Ffu!! rep!acement of !ump ron ore" ) nter s produced ,y us n% coke f nes' ron ore f nes' ! mestone f nes' do!om te' EOF s!a% E f!ew dust" .es des fu!f !! n% the tw n o,ject (es of mpro( n% the product ( ty of .!ast Furnace and reduc n% the coke rate' the usa%e of s nter at .!ast Furnace addresses !ar%er en( ronmenta! aspects ,y waste ut ! <at on n the p!ant" IRON COMPLE> ??BLAST FURNACE= 0)# )tee! 4 m ted' )a!em #orks has two .!ast Furnaces" The + n .!ast Furnace 3 s of 6B2 m5 usefu! (o!ume and + n .!ast Furnace 2 s of 77B m 5 usefu! (o!umes" The techno!o%y was supp! ed ,y CERI)' Ch na" The capac ty of the .F13 s B"6 +T&A" The capac ty of the .F12 s B"9 +T&A" Iron s produced at .!ast Furnace n the ! :u d state' wh ch s ca!!ed *ot +eta!" Th s s e ther transferred to )tee! +e!t n% )hop -)+)/ for con(ert n% nto ! :u d stee! and then , !!ets or to the
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& % Cast n% +ach ne -&C+/ to ,e cast nto p %s" Granu!ated s!a% s the ,y1product from Iron Comp!e$" It s used as a raw mater a! n cement manufactur n% ndustr es" STEEL MA2ING SHOP ??ENERGY OPTIMI@ING FURNACE= 0)# )tee! 4 m ted' )a!em #orks has a B"6 +T&A capac ty Ener%y Opt m < n% Furnace -EOF/' the techno!o%y of wh ch was de(e!oped ,y AORF Techno!o% ca! )er( ces -AT)/ .ra< ! and supp! ed ,y +Fs Tata AORF En% neer n% )er( ces 4 m ted" Now t has another Ener%y Opt m < n% Furnace "e" EOF 2 w th a capac ty B"9 +T&A' the techno!o%y of wh ch was de(e!oped ,y +INITEC .ra< !" At the EOF' hot meta! from .!ast Furnace and so!d meta!! c char%es' %enerated as we!! as purchased' are char%ed and ref ned nto ! :u d stee! ,y us n% o$y%en and f!u$es" Th s so! d char%e percenta%e can ,e up to 5B= ma$ mum" STEEL MA2ING SHOP ??LADLE FURNACE= 0)# )tee! 4 m ted' )a!em #orks has 6 4ad!e Furnace -4F/ of 67T' 97T' 97T and 97T capac ty respect (e!y" 4F 3 wh ch was de(e!oped ,y the techno!o%y of A.." 4F 2 E 5 wh ch was de(e!oped ,y the techno!o%y of DANIE4I' Ita!y" 4F 6 wh ch was de(e!oped ,y the techno!o%y of EA)TERN +ETEC' Ao!kata" The 4F fac ! tates further ref n n% of stee! ,y add t on of Ferro a!!oys and pur% n% w th n tro%en F ar%on to ach e(e the chem ca! compos t on of the tar%eted %rades of stee!" It a!so ra ses and ma nta ns the ! :u d stee! temperature to match the work n% re% mes of EOF and Cont nuous Cast n% +ach ne"

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STEEL MA2ING SHOP ??VACUUM DEGASSING= 0)# )tee! 4 m ted' )a!em #orks has a (acuum de%ass n% p!ant" Th s s present n the )+) re% on" )a!em #orks has two @acuum de%ass n% -@D/" The capac ty of the ,oth @D 3E 2 s 97T" @D 3 wh ch was de(e!oped ,y the techno!o%y of DANIE4I' Ita!y" @D 2 was de(e!oped ,y the techno!o%y of EA)TERN +ETEC' Ao!kata" Th s fac ! tates n the comp!ete remo(a! of %aseous products from the hot stee! meta!" STEEL MA2ING SHOP ?? CONTINUOUS CASTING MACHINE= 0)# )tee! 4 m ted' )a!em #orks has two Cont nuous Cast n% +ach ne -CC+/" CC+ 1 has a capac ty of B"6 +T&A s supp! ed ,y +Fs CONCA)T Ind a 4td" w th dou,!e rad us of >F39 meters and w th a capa, ! ty of cast n% , !!ets F ,!ooms n the s <es ran% n% of 3BB' 35B and 39B ):uares" CC+ 7 has a capac ty of B"9 +T&A' the techno!o%y of wh ch was de(e!oped ,y DANIE4I' Ita!y" # th dou,!e rad us of 32 F 39"7 F 5B +eters rad us ,!oom caster capa,!e of cast n% 39Bmm to 56B$6BB mm" BAR AND ROD MILL= The .ar and Rod + !! -.R+/ s h %h!y (ersat !e and cons sts of 22 stand cont nuous m !! preceded ,y a 5 1 h %h rou%h n% stand w th a capa, ! ty of produc n% B"6 +T&A ,ars and rods n the s <es of 9 mm to 77 mm" .R+ wh ch was de(e!oped ,y the techno!o%y of DE+AG F +or%an" The fo!!ow n% fac ! t es are pro( ded at .R+' the mater a! f!ow ,e n% n the se:uence as descr ,ed"
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B"67 + !! on Tonnes per annum .ar E Rod + !! 2 no"s 67 T F hour D #a!k n% hearth Re1heat n% Furnaces 3? )tand *or <onta! D @ert ca! Conf %urat on" Coo! n% ,ed ! ne for ,ars F F!ats" OTHERS ?? AIR SEPARATION PLANT= 0)# )tee! 4 m ted' )a!em #orks has two A r )eparat on &!ant" The A r )eparat on &!ant -A)& 3/ has a capac ty of 37B T&D" ItGs supp! ed ,y +Fs Aa fen% A r )eparat on Factory 4 m ted' Ch na" The A r )eparat on &!ant -A)& 2/ has a capac ty of 67B T&D" ItGs supp! ed ,y AIR 4I8UIDE *HD" O$y%en' N tro%en and Ar%on s produced ,y cryo%en c process ,ased on the pr nc p!es of d fferent ! :uefy n% and ,o ! n% po nts of %ases" The product on can ,e n %aseous and ! :u d modes" &resent!y' o$y%en and n tro%en w th a pur ty of a,o(e >>"7= and >>">7= respect (e!y are ,e n% %enerated" The p!ant has ,een pro( ded w th a most modern D str ,uted Contro! )ystem -DC)/ for operat on of p!ant and on! ne contro! of parameters nc!ud n% %as ana!ys s" The %ases are consumed n the p!ant e$cess %as %enerated s marketed" OTHERS ?? PO1ER PLANT= 0)# )tee! 4 m ted' )a!em #orks has three &ower &!ants" The &ower &!ant 3 has a capac ty of ;"; +#' cons st n% of 2 ,o !ers' 2 Tur,o .!owers -one at use p!us one as stand1,y/ and 2 Tur,o Generators" The &ower &!ant 2 s of capac ty 5B +# and s a coa! ,ased one" The &ower &!ant 5 s a!so of capac ty 5B +#' whereas here the p!ant s ,ased on .F %as and Coke O(en F!ue %as"

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9.7. PRODUCTION DETAILS=


0)# )TEE4 4I+ITED' )A4E+ #ORA) s a modern p!ant w th

techno!o% es and nfrastructure for produc n% One + !! on tons" They ha(e produced ;9297B +T stee! n 2BB>13B and ;?9762 +T of *ot meta!" The techno!o%y and mach nery ha(e ,een sourced from !ead n% supp! ers n the wor!d" & % Iron Comp!e$ cons sts of a ,<& )-/3$' &( B%!4, F-')!"$4 <+,# ,#$ A'&8-",+&) "!A!"+,B &( 1.0 M+%%+&) TPA. T<& )-/3$' &( S+),$' P%!),4 <+,# ,#$ A'&8-",+&) "!A!"+,B &( 1.90 M+%%+&) TPA !)8 7 S,'!)8 P+* C!4,+)* M!"#+)$4. 0)# )tee! 4 m ted' )a!em #orks s one of the p!ants n INDIA to ntroduce Ener%y Opt m < n% Furnace" Recent!y the , !!ets n the s <e of 3BB$3BB' 35B$35B' 39B$39B' 27B$27B E 56B$6BB mm D . !!ets F .!ooms 39B' 2BB' 22B' 53B mm 1 Rounds are ,e n% produced" The standard !en%th of the , !!et s 9 meter" The Grades produced are' 3" + !d stee!' 2" Co!d heat n% :ua! ty' 5" * %h car,on stee!' 6" +ed um car,on stee!' 7" E!ectrode :ua! ty' 9" 4ow a!!oy and for% n% stee!"

13

&roducts from 0)# )TEE4 4I+ITED' )A4E+ #ORA) are' Types # re Rods and Rounds *e$a%ons and ):uares F!ats-)pr n% stee!/ ) <e 9mm177mm 32mm179"7mm # dth up to 327mm

GRADES AND ITS SPECIFICATION=


Grades E!ectrode 8ua! ty # re Rods spec f cat on A!! Types

4ow Car,on # re Rods -Genera! F )pec a!/A!! Types * %h Car,on # re Rods Co!d *eat n% 8ua! ty Rounds * %h Tens !e .ars )ta n!ess )tee! A!! Types AI)I 1 3B3B' 3763 E 636B I) >93 )T 7? *T )T 77 *T AI)I 5B6F539

4. SINTER PLANT=
The funct on of the ) nter &!ant s to supp!y the ,!ast furnaces w th s nter' a com, nat on of ,!ended ores' f!u$es and coke wh ch s part a!!y IcookedG or s ntered" In th s form' the mater a!s com, ne eff c ent!y n the ,!ast furnace and a!!ow for more cons stent and contro!!a,!e ron manufacture" F %ure 3 shows a s mp! f ed d a%ram of a s nter p!ant"
14

+ater a!s enter the s nter p!ant from stora%e , ns" They are m $ed n the correct proport ons us n% we %h hoppers' one per stora%e , n' e$cept for the return f nes for wh ch an mpact meter s used nstead" #e %h n% s cont nuous' as s the who!e s nter n% process" The we %hed mater a!s pass a!on% a con(eyor to the m $ n% drum where water s added e ther manua!!y or as a ca!cu!ated percenta%e of the we %ht of mater a! enter n% the drum" The mo sture content of the coke s measured n the strand ro!! feed hopper and used to tr m the secondary water f!ow rate" The m $ permea, ! ty s a!so measured and used to mod fy the amount of water re:u red" The m $ mater a! s fed onto the strand from the hopper ,y a ro!! feeder" The ,ed depth s set and kept constant ,y adjust n% the cut1off p!ate wh ch s f tted w th pro,es to sense the depth of mater a! and automat ca!!y (ary the ro!! feeder speed" The :uant ty of mater a! n the feed hopper tse!f s he!d constant ,y automat c adjustment of the feed rates from the nd ( dua! raw mater a! , ns" "

15

4.1. JS1 SINTER PLANT=


There are two s nter p!ants w th a capac ty of 3"27 m !! on T&A" ) nter n% s essent a!!y a process of heat n% of f ne part c!es to the sta%e of nc p ent fus on -temperature ! tt!e ,e!ow the me!t n% po nt/ for the purpose of a%%!omerat n% them nto !umps" In Iron ore s nter n% t produces stron% ,ut porous a%%!omerate from uncompacted mass" .es des fu!f !! n% the tw n o,ject (es of mpro( n% the product ( ty of .!ast Furnace and reduc n% the coke rate' the usa%e of s nter at .!ast Furnace addresses !ar%er en( ronmenta! aspects ,y ut ! <at on of wastes %enerated n the p!ant" ) nter n% of ron ore f nes s carr ed out on tra(e!! n% %rate mach nes runn n% on a cont nuous ,as s" The top !ayer of s nter ,ed s heated to temperature of 3B7B to 337BJC ,y us n% .FG ,urners" F na!!y coo! n% of s nter s carr ed out w th the a d of c rcu!ar coo!er" The raw mater a!s for s nter are' 3" Iron ore f nes 2" 4 mestone f nes 5" Do!om te f nes 6" Coke ,ree<e 7" F!ue dust' GC& s!ud%e' m !! sca!e 9" Return f nes"

4.7. SINTERING=
) nter n% s a method for mak n% o,jects from powder' ,y heat n% the mater a! n a s nter n% furnace ,e!ow ts me!t n% po nt -so! d state s nter n%/ unt ! ts part c!es adhere to each other" ) nter n% s trad t ona!!y used for manufactur n% ceram c o,jects' and has a!so found uses n such f e!ds as powder meta!!ur%y"

16

A%%!omerat on ,y s nter n% s ach e(ed ,y the app! cat on of heat wh ch resu!ts n the con(ers on of ore f nes nto !ar%e' hard' porous !umps" The format on of such !umps s caused ,yK -a/ An nc p ent fus on of ore part c!es at the contact surface wh ch , nds them to%etherL -,/ Format on of d ffus on ,onds throu%h recrysta!! <at on and crysta! %rowth of hemat te and ma%net te wh ch keep the part c!es to%ether w thout me!t n%" Com,ust on of sma!! s <ed coke ,ree<e wh ch are nt mate!y m $ed w th mo stened ore f nes" Due to comp!ete com,ust on of car,on' a temperature of 35BB136BB de%"C s eas !y atta ned" Th s process s performed common!y Dw %ht14!oyd type cont nuous tra(e!! n% %rate mach nes" .efore char% n% the m $ the %rates are n t a!!y co(ered w th 617 cm th ck !ayer of coke free return s nter of s <e 13B' M?mm n order to pre(ent !eaka%e as we!! as to protect the %rates from o(erheat n%" ) nter m $ usua!!y conta ns other mater a!s ! ke f!ue dust' return f nes' ! mestoneFdo!om te"etc" A,out 61? percent coke ,ree<e n the s nter m $ shou!d suff ce to ra se the temperature to 36BB de%"C The preheat n% of !ayers ,e!ow the com,ust on <one resu!ts n the e(aporat on of mo sture and hydrated water and d ssoc at on of car,onates" The rate of s nter n% s (ery fast and depend n% upon the permea, ! ty and th ckness of the ,ed t takes 3712B m nutes for comp!et on"

17

For atta n n% opt mum permea, ! ty the water content of the s nter m $ may ran%e from 7 D 2B percent' the content ncreas n% w th ncreas n% de%ree of f neness" For ade:uate (o da%e and heat transfer the ore s <e shou!d not e$ceed 9 mm and coke and ! mestone 5 mm" For a % (en fue! rate f the coke s <e s too !ar%e' a !oca! o(erheat n%' e$cess (e ! :u d format on and reduct on of ron o$ des to d ff cu!ty reduc ,!e faya! te can occur" The opt mum coke rate (ar es ,etween 6 1? percent to % (e at !east 97 D ;B percent of M32 mm fract on n the f n shed s nter" The amount of ! mestone added depends upon the ,as c ty' reduc , ! ty and stren%th of the s nter des red" It s much cheaper to ca!c ne ! mestone n the s nter strand w th !ow cost fue! than n the ,!ast furnace"

4.9. TYPES OF SINTER=


) nters are d ( ded nto two ,road c!assesK 1. NON C FLU>ED OR ACID SINTER= Those where no f!u$ s present n the ore or s added 7. FLU>ED SINTER=

18

Those where suff c ent f!u$ has ,een added or s present n the ore" Depend n% upon the re!at (e amounts of ,ases and ac ds' these are further cate%or <ed nto two su,1c!asses accord n% to ,as c tyK (!). SELF0FLU>ING SINTER= Those where suff c ent f!u$ has ,een added n the s nter m $ to pro( ded a ,as c ty that s des red n the f na! s!a%' tak n% nto cons derat on on!y the ,urden ac ds" An e$tra f!u$ s added n the ,urden wh !e char% n% to cater to coke ash ac ds" (3). SUPER0FLU>ED SINTER= In such s nters' an add t ona! f!u$ s added to the m $ to pro( de for the des red f na! s!a% ,as c ty' tak n% nto account the ac ds content of ,oth the ore as we!! as coke ash" If any f!u$ s natura!!y present n the ores' then they are ca!!ed se!f1f!u$ n% ores"

4.4. BONDING=
1. SLAG OR FUSION BOND= &art a! or comp!ete em,edd n% of crysta!! ne const tuents n the matr $ of a fused %!assy me!t' the e$tent depend n% upon the (o!ume and wetta, ! ty of the ! :u d face" The ,ond stren%th depends upon the amount of %!ass and the amounts and types of the const tuents" Th s depends upon the fue! rate and mpur t es ) O2' CaO' +%O and A!2O5' added present" 7. DIFFUSION BOND= Recrysta!! sat on and crysta! %rowth of *emat te -and +a%net te/" *emat te d ffus on p!ays an mportant ro!e' espec a!!y a,o(e 327B135BB De%"C' ,ecause of
19

surface mo, ! ty at h %h temperature" D ffus on ,onded s nters are more porous' access ,!e to reduc ,!e %ases and hence eas !y reduc ,!e"

SINTER HANDLINGK
After the end of the strand' the s nter passes throu%h a sp ked ro!! crusher and the hot screens to the rotat n% c rcu!ar coo!er" A num,er of fans are usua!!y used for coo! n%' and the speed of the coo!er s determ ned ,yK

)trand speed .ed depth The f nes remo(ed ,y the hot screens are con(eyed to the return f nes , n"

After coo! n%' the s nter s passed nto the d schar%e ,unker" At th s sta%e' the !e(e! s contro!!ed ,y (ary n% the out!et feed rate -usua!!y ( ,ro feeders/" The s nter then passes to the co!d screen n% area' where t s passed throu%h crushers and screens to produce part c!es n a spec f c s <e ran%e" ) nter ,e!ow the re:u red s <e passes o(er a ,e!t we %her and returns w th the hot f nes to the return f nes , n"

4.5. DUALITY OF SINTER=


The a m of s nter n% s to a%%!omerate the ron ore f nes" Once the ,enef c a! effects of s nter as a ,!ast furnace ,urden were rea! <ed' the phys ca! propert es and chem ca! const tut on of s nter came to ,e e$am ned more c!ose!y" The understand n% of the dea! ,!ast furnace propert es of ,urden and the poss , ! t es of ach e( n% these n the s nter de(e!oped hand n hand" The o,ject (e of s nter n% therefore en!ar%ed and these are nowK 3" To ncrease the s <e of ore f nes to a !e(e! accepta,!e to the ,!ast furnace" 2" To form a stron% a%%!omerate w th h %h ,u!k reduc , ! ty" 5" To remo(e (o!at !es ! ke CO2 form car,onates' *2O from hydro$ des or su!phur from su!ph des type of ore f nes a!on% w th the r a%%!omerat on"
20

6" To ncorporate f!u$ n the ,urden" Out of the a,o(e four a ms f rst one s must" The e$tent to wh ch the second o,ject s met w !! (ery much depend on the nature of the ore and other econom cs cons derat on of carry n% out the process of s nter n%" The remo(a! of (o!at !es s on!y nc denta!" The ma n attent on s therefore focused on to the e$tent to wh ch f!u$ can ,e ncorporated n the s nter m $ w thout n any way' jeopard < n% other propert es of the resu!tant s nter" Incorporat on of f!u$ n the ,urden n th s way rather than ts add t on as a separate char%e mater a! %reat!y mpro(es the ,!ast furnace performance' s nce the format on of s!a% then ,ecomes re!at (e!y easy and t forms at the correct !e(e! n the ,!ast furnace" The ma n natura! f!u$es used for ron mak n% n ,!ast furnace are ! mestone and do!om te" These f!u$es are char%ed e ther n the ,!ast furnace n !ump form or throu%h s nter" In the !ater case the f!u$es ca!c ned dur n% s nter n% and enter the ,!ast furnace n a com, ned form a!on% w th the o$ de ,urden" Th s reduces the therma! !oad n the ,!ast furnace as a resu!t of pr or ca!c nat ons outs de the furnace and thus reduces the coke rate" 4 mestone s composed ma n!y of ca!c um car,onate and do!om te s a dou,!e car,onate of ca!c um and ma%nes um" "e" CaCo5 and +%Co5"

4.6. SINTER DUALITY AFFECTING BLAST FURNACE PROCESS


4.6.1. ALUMINA CONTENT=
The e$tent of a!um na content shou!d ,e ma nta ned to the opt mum !e(e! to contro! the :ua! ty of s nter" E$cess a!um na content ad(erse!y affects the s nter :ua! ty" As a resu!t t a!so nf!uence on the product ( ty of the ,!ast furnace too" A!um na content n the ran%e of 312= s des red" E$cess a!um na !eads to makes the s!a% more refractory and th s pro,!em s o(ercome ,y ncreas n% the ,as c ty -CaoF) O2/" It !eads to ncrease the s!a% (o!ume' decreases product ( ty' ncrease the coke rate
21

A!um na content s the major concern n 0)# )TEE4 4I+ITED' )A4E+ #ORA) s nter p!ant" To contro! the a!um na content add t on of coke ,ree<e s m n m <ed" The other contro!! n% measures wh ch are used are % (en ,e!ow 3" Imported ! me stone s used" -#h ch has !ow ! me content/' 2" Coke ,ree<e consumpt on was reduced ,y ncreas n% the f $ed car,on content' 5" A!um na content n Fe ore f nes s a!so restr cted to ma$ 5"7="

4.6.7. F$O CONTENT=


The :ua! ty of s nter n terms of FeO content s %n f cant!y affects the compos t on of the hot meta! de! (ered from the ,!ast furnace" The ma n source of FeO n s nter s ron ore f nes' m !! sca!es" The FeO content of the raw mater a!s ha(e a s %n f cant mpact on the ,urn throu%h po nt and tum,!er nde$" .urn throu%h temperature and tum,!er nde$ wou!d ncreases w th ncreas n% amount of FeO content n the s nter raw mater a!" In 0)# )TEE4 4I+ITED' )A4E+ #ORA) t a med at the ran%e of ? D 33= of FeO content"

4.6.9. TUMBLER INDE>=


Th s s one of the most mportant (ar a,!es to determ ne the stren%th of the s nter" The tum,!er nde$ of the s nter s est mated ,y us n% tum,! n% test" The test essent a!!y cons sts of tum,! n% a standard we %ht of a s nter of certa n s <e n a standard drumL tum,! n% s carr ed out at a standard speed for a f $ed num,er of re(o!ut ons" The percenta%e mater a! pass n% throu%h or reta ned on a certa n s e(e s the nde$" A su ta,!e tum,!er nde$ can ,e spec f ed to ensure to!era,!e
22

m n mum de%radat on of the s nter dur n% the hand! n%" In %enera! h %her s the tum,!er nde$ the ,etter the s nter w !! stand dur n% hand! n%" Genera!!y pe!!et <ed ron ore f nes has h %h tum,!er nde$ compared s ntered ron ore" In 0)# )TEE4 4I+ITED' )A4E+ #ORA) the tum,!er nde$ s ca!cu!ated n the NRF !a,oratory" One samp!e of s nter s taken for ana!ys s of tum,!er nde$ e(ery day" The tar%et for tum,!er nde$ s M;B="

4. . ADVANTAGES OF SINTERING=
ACID SINTER= " " " (" A%%!omerat on of f nes nto hard' stron% and rre%u!ar porous !umps wh ch % (e %ood ,ed permea, ! ty" E! m nat on of 9B1;B percent of ore su!phur and arscen c dur n% s nter n%" E! m nat on of mo sture' hydrated water and other (o!at !es" Increase n soften n% temperature and narrow n% down of the soften n% ran%e" FLU>ED SINTER=
"

Ca!c nat on of ! mestone ns de the 3%!4, (-')!"$ s (ery e$pens (e of car,on" Appro$ mate!y 9B1;1 A% CF3BB A% of Co 2 -25B A%"CaCo5/ are sa(ed ,y transferr n% the ca!c nat ons to s nter strand" 4 me ncreases the act ( ty coeff c ent of FeO n the s ! cate and ncreases s nter reduc , ! ty" )uper1f!u$ n% sa(es much more coke n the 3%!4, (-')!"$"
23

" "

("

4 me n s nter sta, ! <es the ! :u dus temperature of the pr mary FeO1 A!2O51) O2 s!a% the me!t n% po nt of wh ch wou!d otherw se r se steep!y as the FeO s reduced n the ,osh" 4 me1r ch ,osh s!a% h nders reduct on of s ! ca' a,sor,s (apor <ed s ! con and su!phur to produce !ow1) '!ow1) ron" &r mary s!a% formed from f!u$ed s nter possesses !ower ( scos ty and ! :u dus temperature and more un form compos t on and hence perm ts smoother furnace operat on" ) nter n% rate s h %her than n ac d s nters" * %h ,!ast furnace product ( ty' ,etter than e(en w th pe!!ets"

(" ("

( " ( "

5. BLAST FURNACE=
A ,!ast furnace s a type of meta!!ur% ca! furnace used for sme!t n% to produce ndustr a! meta!s' %enera!!y ron" In a ,!ast furnace' fue! and ore are cont nuous!y supp! ed throu%h the top of the furnace' wh !e a r -w th o$y%en enr chment/ s ,!own nto the ,ottom of the cham,er' so that the chem ca! react ons take p!ace throu%hout the furnace as the mater a! mo(es downward" The end products are usua!!y mo!ten meta! and s!a% phases tapped from the ,ottom' and f!ue %ases e$ t n% from the top of the furnace"

.!ast furnaces are to ,e contrasted w th a r furnaces' wh ch were natura!!y asp rated' usua!!y ,y the con(ect on of hot %ases n a ch mney f!ue" Accord n% to th s ,road def n t on' ,!oomer es for ron' ,!ow n% houses for t n' and sme!t m !!s for !ead' wou!d ,e c!ass f ed as ,!ast furnaces" *owe(er' the term has usua!!y ,een ! m ted to those used for sme!t n% ron ore to produce p % ron' an ntermed ate mater a! used n the product on of commerc a! ron and stee!"

24

The ,!ast furnace rema ns an mportant part of modern ron product on" .!ast furnaces are h %h!y eff c ent' nc!ud n% Cowper sto(es to pre1heat the ,!ast a r and emp!oy reco(ery systems to e$tract the heat from the hot %ases e$ t n% the furnace" Compet t on n ndustry dr (es h %her product on rates" The !ar%est ,!ast furnaces ha(e a (o!ume around 77?B m5 -3>B'BBB cu ft/ and can produce around ?B'BBB tonnes -??'BBB short tons/ of ron per week"

Th s s a %reat ncrease from the typ ca! 3?th1century furnaces' wh ch a(era%ed a,out 59B tonnes -6BB short tonnes/ per year" @ar at ons of the ,!ast furnace' such as the )wed sh e!ectr c ,!ast furnace' ha(e ,een de(e!oped n countr es wh ch ha(e no nat (e coa! resources" The purpose of a ,!ast furnace s to chem ca!!y reduce and phys ca!!y con(ert ron o$ des nto ! :u d ron ca!!ed Ohot meta!O" The ,!ast furnace s a hu%e' stee! stack ! ned w th refractory ,r ck' where ron ore' coke and ! mestone are dumped nto the top' and preheated a r s ,!own nto the ,ottom" The raw mater a!s re:u re 9 to ? hours to descend to the ,ottom of the furnace where they ,ecome the f na! product of ! :u d s!a% and ! :u d ron" These ! :u d products are dra ned from the furnace at re%u!ar nter(a!s" The hot a r that was ,!own nto the ,ottom of the furnace ascends to the top n 9 to ? seconds after %o n% throu%h numerous chem ca! react ons" Once a ,!ast furnace s started t w !! cont nuous!y run for four to ten years w th on!y short stops to perform p!anned ma ntenance"

25

5.1. BLAST FURNACE CONSTRUCTION=

26

A modern ,!ast furnace s near!y a 5Bm -a,out 3BB feet/ ta!! we!ded p!ate construct on w th c rcu!ar cross sect on of (ary n% s <es at d fferent !e(e!s" It s !!ustrated n f %" to show the essent a! meta!!ur% ca! des %n features and (ar ous mportant parts of furnace" The cross1the sect ona! area ncreases from the top or
27

downwards' a ma$ mum ,e n% at ,osh !e(e! -mant!e/ t decreases downwards thereafter" The structure of the furnace essent a!!y cons sts of a mass >(e foundat on' the hearth' the ,osh' the mant!e and co!umns' the stack' the raw mater a! hau! n% and char% n% fac ! t es and the top as shown n f %"" The outer we!ded stee! she!! s ! ned from ns de w th refractory ! n n% to stand the sme!t n% cond t ons dur n% ts operat on" &re( ous!y the furnace was supported ,y a ,o$1ca%e ! ke structure' ,ut now t free!y stands on!y on ts foundat on w thout !atera! support"

1. FOUNDATIONS= It s a mass (e stee! re nforced concrete mass part a!!y em,edded ,e!ow the %round !e(e!" It may ,e a,out 37 m n d a and 91? m th ck upon wh ch s p!aced the furnace ,ottom cons st n% a,out 617 m th ck of f re ,r cks"

7. HEARTH= It s a receptac!e to co!!ect the ! :u d s!a% and meta! and s a!so referred to as a cruc ,!e" The o!d pract ce of us n% f re ,r cks for hearth construct on s a!most un (ersa!!y rep!aced ,y car,on ,!ocks" #ater coo!ed copper or stee! p!ates are !a d n the s de wa!!s to protect the ! n n%" The car,on may ,e more than a meter of un form th ckness or a stad um type construct on" In the hearth wa!! are !ocated a tap ho!e for ron'32137 cm n d a and "51"9 m a,o(e the hearth ,ottom !e(e!' and a s!a% notch 3"213"9 m a,o(e the tap ho!e !e(e!' ,ut sta%%ered throu%h a r %ht an%!e n the hor <onta! p!ane" These ho!es are c!osed w th c!ay when not n use and are
28

opened for tapp n% s!a% and meta! as and when necessary" At the top !e(e! of the hearth are !ocated tuyeres un form!y d str ,uted o(er the ent re cross1sect on"

9. BOSH= The top of the ,osh has the ma$ mum d a of furnace and t s the <one of ntense heat" It s a stad um1type construct on w th stee! re nforcement" #ater coo!ed copper or stee! p!ates are nserted at re%u!ar nter(a!s n the furnace ! n n% n th s <one to effect protect on a%a nst h %h temperature" The ntens (e coo! n% of a th n wa!!ed ,osh forms a !ayer of so! d f ed s!a% m $ed %raph te on the ! n n% wh ch n rea! ty protects the ,r ckwork from mo!ten meta! and s!a%"

4. MANTLE AND COLUMNS= The furnace structure a,o(e the ,osh !e(e! s supported on a hea( !y ,raced stee! r n% enc rc! n% the furnace at the top of the ,osh" Th s s ca!!ed the mant!e wh ch s supported ,y un form!y spaced upr %ht hea(y co!umns' wh ch are f rm!y anchored n concrete foundat on at the ,ottom"

5. STAC2= It s frustum of a hu%e cone mounted on the mant!e and e$tends to the top of the furnace" The furnace top that s ,e!!' the char% n% arran%ement' the %as off1 takes' etc"are mounted on top of the stack" The stack s we!ded stee! p!ate
29

construct on ! ned from ns de to a th ckness of a,out a meter of hard f re,r cks" F!at water coo!ed p!ates are nserted n the part of the stack ! n n%" The top 215 m he %ht' wh ch s stack! ne' s protected from a,ras on caused ,y the fa!! n% char%e ,y pro( d n% armour p!ates on the nner surface of ! n n%"

6. TUYERE AND BUSTLE PIPE= Immed ate!y a,o(e the hearth are !ocated the tuyeres throu%h wh ch hot a r ,!ast s ,!own for fue! com,ust on see f %""The num,er tuyeres w th the (ar ous of s <e of furnace" Usua!!y t s any e(en num,er ,etween 3B12B and s un form!y spaced a!! o(er the per phery" A r from hot ,!ast sto(es s supp! ed to a hu%e c rcu!ar p pe enc rc! n% the furnace at the ,osh !e(e!" Th s s ca!!ed the ,ust!e p pe" The nd ( dua! tuyeres are connected to the ,ust!e p pe wh ch' ,y ( rtue of ts enormous s <e' e:ua! <es the pressure of the ,!ast at a!! the tuyeres" It s n fact ts (ery purpose"

. BELL AND HOPPER= A ,e!! and the hopper or the cup and cone arran%ement' s ca!!ed' was common!y used n ,!ast furnaces for char% n% the so! d char%e" It a!!owed smooth char% n% w thout the off1%as !eak n% out nto open" The off1%as' wh ch has some fue! (a!ue ,y ( rtue of ts CO content and' wh ch s a(a !a,!e n !ar%e amount cou!d thus ,e co!!ected ' c!eaned and ut ! <ed as a ,y1product fue!' for pre1heat n% the ,!ast and the st !! !efto(er part' e!sewhere n the p!ant" Th s des %n !asted for a !on%t me' w th or w thout some add t ona! fac ! t es to mpro(e upon the char%e d str ,ut on chute known as &AU4 #URT* DI)TRI.UTOR' s!ow!y rep!aced the
30

trad t ona! dou,!e ,e!! arran%ement s nce the 3>?BGs and the rep!acement was near!y tota! ,y the ,e% nn n% of twenty f rst century' e$cept some e$cept ona! or the sma!! furnace" Th s mpro(ed the ,urden d str ,ut on ns de the furnace and there,y mpro(ed the ,!ast furnace eff c ency cons dera,!y" Towards the !atter ha!f of the f rst decade of the twenty1f rst century a st !! ,etter mod f ed and more eff c ent top has ,een des %ned and put nto use" Th s s known as %am,!e top' wh ch has ,een des %ned open ,y the ) emens1@oest1A!p ne %roup" New ,!ast furnaces or those ,e n% modern <ed ha(e started adopt n% t as a ,etter a!ternat (e" The C1furnace of Tata stee! s %o n% to adopt t dur n% ts des %n mod f cat ons to ,e carr ed out n 2BB;1B?" #hen h %h pressure was ntroduced se(era! comp!e$ sea!s had to ,e used on the top w th dou,!e ,e!! arran%ement" The &au!1worth ,e!!1!ess top pro(ed (ery effect (e from th s po nt of ( ew as we!!" The %am,!e1top s c!a med to ,e st !! more eff c ent from the po nt of ( ew of adopt n% h %h top pressure" It s c!a med to ,e more effect (e for far ,etter char%e d str ,ut on and eas er mechan ca! ma ntenance"

8. OFF0TA2E= There are four e$haust p pes wh ch are connected to the furnace top e(en!y at four po nts" These r se (ert ca!!y up a,o(e the furnace top and then jo n to a , %%er s n%!e p pe known as the down comer wh ch de! (ers the %as to the %as c!ean n% system "e" dust catcher"
31

;. HOT BLAST STOVE= A r ,!ast s preheated to a temperature of ;BB135BB C n Cowper re%enerator sto(es" A set of three or four re%enerators s pro( ded for each furnace" The sto(e s a,out 91> m n d a and 5B157 m n he %ht" )pec a! th n wa!!ed ,r cks are6 used to construct the checker work n the sto(e" Dur n% one sto(e s Ion1,!astG' heat n% t' wh !e the rema n n% two or three are Ion1%asG that s %ett n% themse!(es heated ,y ,urn n% the c!eaned ,!ast furnace %as" The ear! er sto(e had near!y 7BBBm 2 as the checker surface area for heat e$chan%e ,ut the modern one may ha(e a,out f (e t mes th s much" The therma! eff c ency o2 such a sto(e s around ?B1>B=")e(era! (a!(es are pro( ded on the sto(e assem,!y to carry out the chan%eo(er from %as to a r and ( ce (ersa smooth!y" )team dr (en centr fu%a! ,!owers are %enera!!y emp!oyed to supp!y ,!ast at a un form rate to the furnace" These are !oBcated n the ,!ower house near the furnace"

5.7. BLAST FURNACE PROCESS=


Iron o$ des can come to the ,!ast furnace p!ant n the form of raw ore' pe!!ets or s nter" The raw ore s remo(ed from the earth and s <ed nto p eces that ran%e from B"7 to 3"7 nches" Th s ore s e ther *emat te -Fe2O5/ or +a%net te -Fe5O6/ and the ron content ran%es from 7B= to ;B=" Th s ron r ch ore can ,e
32

char%ed d rect!y nto a ,!ast furnace w thout any further process n%" Iron ore that conta ns a !ower ron content must ,e processed or ,enef c ated to ncrease ts ron content" &e!!ets are produced from th s !ower ron content ore" Th s ore s crushed and %round nto a powder so the waste mater a! ca!!ed %an%ue can ,e remo(ed" The rema n n% ron1r ch powder s ro!!ed nto ,a!!s and f red n a furnace to produce stron%' mar,!e1s <ed pe!!ets that conta n 9B= to 97= ron" ) nter s produced from f ne raw ore' sma!! coke' sand1s <ed ! mestone and numerous other stee! p!ant waste mater a!s that conta n some ron" These f ne mater a!s are proport oned to o,ta n des red product chem stry then m $ed to%ether" Th s raw mater a! m $ s then p!aced on a s nter n% strand' wh ch s s m !ar to a stee! con(eyor ,e!t' where t s %n ted ,y %as f red furnace and fused ,y the heat from the coke f nes nto !ar%er s <e p eces that are from B"7 to 2"B nches" The ron ore' pe!!ets and s nter then ,ecome the ! :u d ron produced n the ,!ast furnace w th any of the r rema n n% mpur t es %o n% to the ! :u d s!a%" The coke s produced from a m $ture of coa!s" The coa! s crushed and %round nto a powder and then char%ed nto an o(en" As the o(en s heated the coa! s cooked so most of the (o!at !e matter such as o ! and tar are remo(ed" The cooked coa!' ca!!ed coke' s remo(ed from the o(en after 3? to 26 hours of react on t me" The coke s coo!ed and screened nto p eces ran% n% from one nch to four nches" The coke conta ns >B to >5= car,on' some ash and su!fur ,ut compared to raw coa! s (ery stron%" The stron% p eces of coke w th a h %h ener%y (a!ue pro( de permea, ! ty' heat and %ases wh ch are re:u red to reduce and me!t the ron ore' pe!!ets and s nter" The f na! raw mater a! n the ron mak n% process s ! mestone" The ! mestone s remo(ed from the earth ,y ,!ast n% w th e$p!os (es" It s then crushed and screened to a s <e that ran%es from B"7 nch to 3"7 nch to ,ecome ,!ast furnace
33

f!u$" Th s f!u$ can ,e pure h %h ca!c um ! mestone' do!om t c ! mestone conta n n% ma%nes a or a ,!end of the two types of ! mestone" The ron ore' pe!!ets and s nter are reduced wh ch s mp!y means the o$y%en n the ron o$ des s remo(ed ,y a ser es of chem ca! react ons" These react ons occur as fo!!owsK .e% ns at ?7BJ F 5 Fe2O5 M CO P CO2 M2 Fe5O6 .e% ns at 33BBJ F Fe5O6 M CO P CO2 M 5 FeO .e% ns at 35BBJ F FeO M CO P CO2 M Fe or FeO M C P CO M Fe At the same t me the ron o$ des are %o n% throu%h these pur fy n% react ons' they are a!so ,e% nn n% to soften then me!t and f na!!y tr ck!e as ! :u d ron throu%h the coke to the ,ottom of the furnace" The coke descends to the ,ottom of the furnace to the !e(e! where the preheated a r or hot ,!ast enters the ,!ast furnace" The coke s %n ted ,y th s hot ,!ast and mmed ate!y reacts to %enerate heat s fo!!owsK C M O2 P CO2 M *eat

34

) nce the react on takes p!ace n the presence of e$cess car,on at a h %h temperature the car,on d o$ de s reduced to car,on mono$ de as fo!!owsK C O2M C P 2CO The product of th s react on' car,on mono$ de' s necessary to reduce the ron ore as seen n the pre( ous ron o$ de react ons" The ! mestone descends n the ,!ast furnace and rema ns a so! d wh !e %o n% throu%h ts f rst react on s fo!!owsK CaCO5 P CaO M CO2 Th s react on re:u res ener%y and starts at a,out 39BBJF" The CaO formed from th s react on s used to remo(e su!fur from the ron wh ch s necessary ,efore the hot meta! ,ecomes stee!" Th s su!fur remo( n% react on sK Fe) M CaO M C P Ca) M FeO M CO The Ca) ,ecomes part of the s!a%" The s!a% s a!so formed from any rema n n% ) ! ca -) O2/' A!um na -A!2O5/' +a%nes a -+%O/ or Ca!c a -CaO/ that entered w th the ron ore' pe!!ets' s nter or coke" The ! :u d s!a% then tr ck!es throu%h the coke ,ed to the ,ottom of the furnace where t f!oats on top of the :u d ron s nce t s !ess dense" Another product of the ron mak n% process' n add t on to mo!ten ron and s!a%' s hot d rty %ases" These %ases e$ t the top of the ,!ast furnace and proceed throu%h %as c!ean n% e:u pment where part cu!ate matter s remo(ed from the %as and the %as s coo!ed" Th s %as has a cons dera,!e ener%y (a!ue so t s ,urned as a
35

fue! n the Ohot ,!ast sto(esO wh ch are used to preheat the a r enter n% the ,!ast furnace to ,ecome Ohot ,!astO" The ,!ast furnace s a counter1current rea!tor where so! ds descend and %ases ascend" In th s reactor there are numerous chem ca! and phys ca! react ons that produce the des red f na! product wh ch s hot meta!" TBA+"!% #&, /$,!% "#$/+4,'B (&%%&<4K Iron -Fe/ ) ! con -) / )u!phur -)/ +an%anese -+n/ &hosphorus -&/ T tan um -T / Car,on -C/ P >5"7 1 >7"B= P B"5B 1 B">B= P B"B27 1 B"B7B= P B"77 1 B";7= P B"B5 1 B"B>= P B"B2 1 B"B9= P 6"3 1 6"6=

36

5.9. BLAST FURNACE REACTIONS=

The reduct on and sme!t n% of ron ore s done ma n!y n the ron ,!ast furnace" The ,urden char%ed at the top of the furnace cons sts pr mar !y of ron ore' f!u$ and coke" The reduc n% %as car,on mono$ de and the heat re:u red for the sme!t n% of the ore are %enerated at the ,ottom of the furnace ,y ,!ow n% preheated a r nto the coke ,ed" The s!a% and meta! accumu!ate as two ! :u d !ayers at the ,ottom of the furnace" In order that eff c ent con(ers ons of reactants to products occur' there s an o(era!! chem ca! st och metry' wh ch must ,e met" In add t on' spec f c therma! re:u rements must a!so ,e sat sf ed to perm t the endotherm c react ons to proceed and the products ,rou%ht to the r f na! temperatures" The ,!ast furnace can ,e con(en ent!y d ( ded nto three <ones for a study of the phys ca! and chem ca! react ons occurr n% there n" These <ones are as fo!!owsK o o o The upper or pre1 heat n% or preparat on <one The m dd!e or nd rect reduct on or therma! reser(e or sotherma! <one The !ower or process n% or me!t n% or d rect reduct on <one

5.9.1. REACTIONS IN THE UPPER @ONE= The react ons of pr mary concern n the ron ,!ast furnaces are the reduct on react ons of ron o$ des" The format on of product !ayers dur n% the reduct on of ron ore s we!! known" The %reater the dr ( n% forces for the reduct on and the
37

faster the rate of chem ca! react on' the more pronounced s the format on of the product !ayers"

5 Fe2O5 M CO P CO2M 2 Fe5O6 M 3B"22kca! Fe55O6 M CO P CO2 M 5FeO1 ?";7kca! FeO M CO P CO2 M FeM 5">> kca!

-3/ -2/ -5/

At the same t me the ron o$ des are %o n% throu%h these pur fy n% react ons' they are a!so ,e% nn n% to soften' then me!t and f na!!y tr ck!e down as ! :u d ron throu%h the coke to the ,ottom of the furnace" +a%net te s reduced to wust te ma n!y at ;BB1>BBJC' thermodynam ca!!y car,on depos t on from CO ,y the react on 2CO P CO2 M C M 63"23 kca! -6/

The depos t on occurs predom nant!y n a narrow temperature ran%e 66B1 9BBJ C' the presence of ron and ts o$ des cata!yses the react on" It s a!so poss ,!e for CO to reduce *2O n the upper furnace to a certa n e$tent" CO M *2O P CB2 M *2M >"9? kca! -7/

The decompos t on of car,onates other than those of ca!c um occurs at a re!at (e!y !ow temperature around 6BBJ C" they are of (ery ! tt!e mportance ,ecause modern furnaces are us n% pe!!ets or s nter and these car,onates are ca!c ned outs de"
38

5.9.7. REACTIONS IN THE MIDDLE @ONE= It s a moderate temperature <one where the temperature ran%es ,etween ?BB13BBBJ C" most of the nd rect reduct on of wust te-E:" 5/ occurs n the <one" The COFCO2 rat o of the nact (e <one s a,out 2"5' a (a!ue e$h , t n% e:u ! ,r um w th Fe1FeO -E:"5/" The !ar%er the he %ht of the ?BB13BBBJ C temperature <one' the !on%er the %as1 so! d contact t me at these temperatures and the %reater the de%ree of nd rect reduct on" ) m !ar!y' the h %her the reduc , ! ty of the ore' the more rap d s the reduct on" In short' the rate of reduct on of ore n the m dd!e <one must not ,e a restr ct on for the atta nment of opt mum coke rate"

5.9.9. REACTIONS IN THE LO1ER @ONE= The temperature of the !ower <one s >BB13BBBJ C" a (ar ety of phys ca! and chem ca! processes occurs n th s <one" +ost of the unreduced ron o$ des descend nto the !ower <one as faya! te' ca!c um ferr tes or nterm $ed n the pr mary s!a%" D rect reduct on of ron o$ de proceeds at temperature a,o(e 3BBB JC accord n% toK FeO M CO P Fe M CO2 C M CO2 P 2CO -9/ -;/

The reduct on of ) and T re:u re (ery h %h temperatures wh !e the o$ des of Ca' +% and A! are so sta,!e that they are reduced to a (ery ne%! % ,!e e$tent" The reduct on of +n from ts mono$ de s much more d ff cu!t and occurs at a st !!
39

h %her temperature" The e$tent of reduct on (ar es w th temperature and s!a% ,as c ty" Cr and @ ,eha(e n the same way as +n" +nO M C P +n M CO ) O2 M 2C P ) M 2CO ) M CaO M C P Ca) M CO -?/ ->/ -3B/

A major port on of & s present as tr 1 or tetra1 phosphate of Ca" ) ! ca he!ps n ,reak n% phosphate ,ond" 5CaO"&2O7 M 5) O2 P 5-CaO") O2/ M &2O7 &2O7 M 7C P 2& M 7CO -33/ -32/

6. RA1 MATERIALS USED IN A BLAST FURNACE


Iron ore or *emat te -Fe5O2/' Car,on n the form of CCokeC' and 4 mestone -Ca!c um Car,onate CCaCO5C/ are a!! used n the ,!ast furnace" Iron Ore s me!ted down w th coke' the coke ,urns heat nto the furnace" O$y%en %as s ,!asted n from the s des" The car,on -C/ and o$y%en -O2/ react to form car,on d o$ de %as -CO2/" At h %her temperatures more car,on -C/ s reacted w th the car,on d o$ de -CO2/ to create car,on mono$ de -2CO/" The car,on mono$ de Cstea!sC the o$y%en from the ron o$ de -Fe5O2/' reduc n% the ron o$ de to ron" Due to the mpur t es n the ron' t s ca!!ed Cp % ronC" 4 mestone -CaCO5/ s added to remo(e the mpur t es from the ron" The ! mestone -CaCO5/ reacts w th ma n!y s ! cate n the ron' and ,ecomes ca!c um s ! cate -Ca) O5/ and car,on d o$ de -CO2/" Ca!c um s ! cate s known as Cs!a%C and s used for construct on"

6.1. DUALITY OF CHARGE MATERIAL=


A ,!ast furnace char%e cons sts of coke' ore or s nter' and ! mestone" These
40

mater a!s must ,e n !umps of a certa n s <e -6B19B mm/" 4ar%er !umps pro!on% the process of reduct on and f!u$ n%" )ma!!er !umps ,!ock the f!ue1%as passa%es and pre(ent a un form descent of me!t n% mater a!s n the furnace"

6.7. IRON ORES=


Iron ores are rocks and m nera!s from wh ch meta!! c ron can ,e econom ca!!y e$tracted" The ores are usua!!y r ch n ron o$ des and (ary n co!or from dark %rey' ,r %ht ye!!ow' deep purp!e' to rusty red" The ron tse!f s usua!!y found n the form of ma%net te -Fe5O6/' hemat te -Fe2O5/' %oeth te -FeO-O*//' ! mon te -FeO-O*/"n-*2O// or s der te -FeCO5/" *emat te s a!so known as Onatura! oreO' a name wh ch refers to the ear!y years of m n n%' when certa n hemat te ores conta n n% up to 99= ron cou!d ,e fed d rect!y nto ron1mak n% ,!ast furnaces" Iron ore s the raw mater a! used to make p % ron' wh ch s one of the ma n raw mater a!s to make stee!" >?= of the m ned ron ore s used to make stee!" Ore s a meta! ,ear n% m nera!" The most mportant (ar et es of ron ore areK1 3" 2" 5" 6" +a%net te or ,!ack ron ore *emat te or red ron ore" 4 mon te or ,rown ore" ) der te -FeCO5/"

9"2"3" +AGNETITEK
+a%net te s a ferr ma%net c m nera! w th chem ca! formu!a Fe5O6' one of se(era! ron o$ des and a mem,er of the sp ne! %roup" The chem ca! IU&AC name s ron -II' III/ o$ de and the common chem ca! name s ferrous1ferr c o$ de"

9"2"2" *E+ATITEK
41

*emat te s the m nera! form of ron -III/ o$ de -Fe2O5/' one of se(era! ron o$ des" *emat te crysta!! <es n the rhom,ohedra! system' and t has the same crysta! structure as !men te and corundum" *emat te and !men te form a comp!ete so! d so!ut on at temperatures a,o(e >7BJC"

9"2"5" 4I+ONITEK
4 mon te s an ore cons st n% n a m $ture of hydrated ron-III/ o$ de1 hydro$ de of (ary n% compos t on" The %ener c formu!a s fre:uent!y wr tten as FeO -O*/ Qn*2O' a!thou%h th s s not ent re!y accurate as ! mon te often conta ns a (ary n% amount of o$ de compared to hydro$ de" 4 mon te s hea(y and ye!!ow sh1 ,rown"

9"2"6" )IDERITEK
) der te s a m nera! composed of ron car,onate FeCO5" It takes ts name from the Greek word s deros' R ronS" It s a (a!ua,!e ron m nera!' s nce t s 6?= ron and conta ns no su!fur or phosphorus" .oth ma%nes um and man%anese common!y su,st tute for the ron"

6.9. MANGANESE ORES=


+an%anese ores are used for sme!t n% ferroman%anese' cast ron and p % ron conta n n% a,out 3= +n" +an%anese s present n e ther of ts fo!!ow n% o$ de and car,on teformK &yrosu! te +nO2' ,raun te +n2O5' hausmann te+n5O6 and rhodochros te +nCO5"

6.4. FLU>ES=
F!u$es are added to s nter or char%ed d rect!y nto the ,!ast furnace n order to ! :uefy ore and s nter %an%ue and fue! ash' con(ert n% them to free f!ow n% s!a%
42

that can ,e run of the furnace" The f!u$ s dec ded ,y the %an%ue and ash ana!ys s" The ! mestone s the most popu!ar f!u$ n ,!ast furnace and s nter n% process" The ! mestone char%ed n the ,!ast furnace must ,e n !umps -2719B mm across/' f rm' not prone to f nes and most mportant' free from harmfu! su!phur' phosphorus and s ! ca" Common!y used F!u$esK 3" 2" 5" 4 mestone' 8uart< te' Dun te"

. RESULT AND DISCUSSION=

#e concentrated on the .!ast furnace data n the per od of OCT 10 TO MAR 11 n 0)# .!ast furnace for our study and we compared the effect of .!ast Furnace parameters dur n% d fferent ) nter percenta%es"

43

PRODUCTION RATE=
S+),$' (E) T77 7719B 93197 991;B U;B R!)*$ BF(MT) 3326 32;7 3626 3692 36;7

44

I)($'$)"$= For the s nter amount !ess than 77= the &roduct on per day s 3326 T*+" # th further ncrease of s nter up to ;B=' *ot meta! &roduct on ncreases to 3692 +T" For s nter (a!ues of more than ;B=' the &roduct on ncreases to 36;7 +T" H$)"$, ,#$ '$4-%, "&)"%-8$4 ,#!, <+,# +)"'$!4$ +) A$'"$),!*$ 4+),$', H&, M$,!% P'&8-",+&) +)"'$!4$4 +) %+)$!' '!,$.

S2IP IRON ORE BEARING=


S+),$' (E) T77 7719B 93197 991;B U;B R!)*$ BF (2* F THM) 396B 3955 396B 3975 3973

45

I)($'$)"$= For the s nter amount !ess than 77= the sk p ron ore ,ear n% per T*+ s 396BA%FT*+" For s nter (a!ues more than ;B=' t ncreases to 3973 A%FT*+" Th s ncrease of )k p Iron ,ear n% s due to the !esser Fe= n ) nter compared to Iron Ore due to se!f f!u$ n% n the s nter" *ence the sk p ron ore ,ear n% ncreases w th respect to the ncrease n percenta%e s nter"

FLU> RATE=
S+),$' R!)*$ (E) BF(2* F THM) T77 7719B 93197 991;B U;B 39B ;2 67 6B 59

46

I)($'$)"$= For the s nter amount !ess than 77= the F!u$ rate per T*+ s 39BA%FT*+" # th further ncrease of s nter up to ;B= decreases the F!u$ rate to 6B A%FT*+" For s nter (a!ues more than ;B=' the F!u$ rate decreases to 59 A%FT*+" Reduct on n D rect F!u$ Rate % (es s %n f cant ad(anta%es n .!ast Furnace &rocess such as !esser fue! rate' !esser cost etc" *ence the F!u$ rate decreases w th respect to the ncrease n percenta%e s nter"

SINTER F$ E=
S+),$' (E) T77 7719B 93197 991;B U;B R!)*$ BF (E) 77";? 77";? 77"9; 77">9 79"2>

47

I)($'$)"$= For the s nter amount !ess than 77= the ) nter Fe = s 77";?=" # th further ncrease of s nter up to ;B= ncreases the ) nter Fe = to 77">9" For s nter (a!ues more than ;B=' the ) nter Fe = ncreased to 79"2>" *ence the ) nter Fe = ncreases w th respect to the ncrease n percenta%e s nter"

FUEL RATE=
S+),$' (E) T77 7719B 93197 991;B U;B R!)*$ BF (2* F THM) 9B> 7?7 7;2 7;5 7;;
48

I)($'$)"$= For the s nter amount !ess than 77= the Fue! rate per T*+ s 9B>A%FT*+" For s nter (a!ues more than ;B=' the Fue! rate decreases to 7;; A%FT*+" Th s s one of the ,est ,enef ts wh ch are %ot throu%h ) nter" As 9B = of Tota! )tee! Cost comes throu%h CokeGs cost' decrease n CokeGs consumpt on % (es a major ad(anta%e n Cost econom cs"*ence the Fue! rate decreases w th respect to the ncrease n percenta%e s nter"

BLAST=
S+),$' (E) T77 7719B 93197 991;B R!)*$ BF(2* F THM) 397; 369; 33?6 3395

49

U;B

332>

I)($'$)"$= For the s nter amount !ess than 77= the ,!ast per T*+ s 397;A%FT*+" # th further ncrease of s nter up to ;B= decreases the ,!ast to 3395" For s nter (a!ues more than ;B=' the ,!ast decreased to 332>" *ence the ,!ast rate decreases w th respect to the ncrease n percenta%e s nter"

SLAG VOLUME=
S+),$' R!)*$ (E) T77 7719B 93197 991;B BF(2* F THM) 526 52> 552 55;

50

U;B

566

I)($'$)"$= For the s nter amount !ess than 77= the s!a% (o!ume per T*+ s 526A%FT*+" # th further ncrease of s nter up to ;B= decreases the s!a% (o!ume to 55;" For s nter (a!ues more than ;B=' the s!a% (o!ume ncreases to 566" )!a% @o!ume ncrease s due to the presence of h %her A!2O5 and ) O2 n the ) nter" E(enthou%h s!a% (o!ume ncrease s not fa(oura,!e to .!ast Furnace &rocess' ,y ha( n% a ! m t to the s!a% (o!ume' ) nter = s ncreased for reap n% ma$ mum ,enef ts" *ence the s!a% (o!ume ncreases w th respect to the ncrease n percenta%e s nter"

CONCLUSIONK
Th s deta !ed )tudy on .!ast Furnace &arameters dur n% d fferent ) nter percenta%es ,r n%s out se(era! nterest n% features n the conte$t of .!ast Furnace process" Re%ard n% the product ( ty s concerned' t % (es a d rect ! near rate of ncrease n product on w th respect to the ) nter percenta%e and th s emphas ses the fact that a!! o(er the wor!d ,!ast furnaces are ma$ m s n% ) nter = n the r nput"
51

Re%ard n% the fue! rate s concerned' as we know' reduct on of Coke consumpt on s the pr me o,ject (e of a stee! p!ant' ncrease n ) nter s the ,est opt on for reduct on of Coke consumpt on" As ) nter a!ready a Iha!f cooked productG' the o(era!! re:u rement of Coke comes down drast ca!!y n .!ast Furnaces" # th re%ard to reduct on of F!u$ rate a!so' d rect f!u$ add t on causes se(era! d sad(anta%es to .!ast Furnace &rocess such as h %her fue! consumpt on' h %her ) ! con n the hot meta! etc" .y add n% f!u$es throu%h ) nter a(o ds these d sad(anta%es" # th respect to reduct on n ,!ast rate s concerned' as h %her product ( ty s ach e(ed w th the same amount of ,!ast (o!ume ,!own ns de the furnace' ad(anta%es such as reduct on n .!ast consumpt on' reduct on n power' )team etc" are ach e(ed" F na!!y' we can conc!ude that 0)# .!ast Furnace has adopted the strate%y for ncreas n% the ) nter n the r Input for ach e( n% (ar ous ad(anta%es ! sted a,o(e" Th s s n ! ne w th the nternat ona! standards and we can conc!ude throu%h our paper that they are a,!e to ach e(e the ,enef ts ,y ncreas n% ) nter percenta%e n the r ,urden"

52

REFERENCES= 3" Gupta ) A' Das ) N and Chandra Na( n' Trans Ind Inst +et 48 -3>>7/ p 6B>" 2" Aundu A 4' &rasad ) C' Chottopadhyay D' . shoy A' and &rasad +' )ome aspects of product on of :ua! ty hot meta! at Rourke!a )tee! &!ant' &roc Nat ona!
53

)em nar on RTechno!o% es for Ironmak n%S or%an sed ,y II+' Rourke!a Chapter and Rourke!a )tee! &!ant' Decem,er -2BB3/" 5" Turkdo%an E T' the 3>;? *owe +emor a! 4ecture' the Iron E )tee! )oc ety of A+IE' +eta!!ur% ca! Transact ons . ;B -3>;?/ p 395" 6" A"A". swas' &r nc p!es of ,!ast furnace ron mak n%"

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