Iron Making Course - Blast Furnace

Companhia
Vale do Rio Doce
IRONMAKING COURSE
BLAST FURNACE
August 27th 2010, Belo Horizonte, Brazil
1
Blast Furnace
Metallurgical reactor where the iron

oxides and reducing agents are
transformed to liquid hot metal (pig iron)
and slag is formed from the gangue of
iron burden and the ash of coke.
Thermodynamic conditions (gas composition and temperature) inside blast
furnace allows impurities incorporation as silicon, carbon, phosphorus and
sulphur to pig iron. Another elements go to the slag.
The blast furnace operates in a countercurrent form. The solid burden flows
downward as it reacts with the gases flowing upward. These gases are
generated by coke combustion with air injected in the bottom of the furnace.
The blast furnace metallic burden is composed by lump, sinter and pellets.
Coke is the reducing and fuel agent of the process.
The blast furnace slag can be sold as raw material to cement industry.
Ironmaking Course
Definition of Volume and Productivity
1) Definition of the blast furnace volumes
1) Total Volume: Is the volume of the BF between the bottom

layer of the hearth and the stock line (zero level burden)
2) Inner Volume: Is the volume of the BF between the taphole
level into the hearth and the stock line (zero level burden)
3) Work volume: is the volume of the BF between the tuyere
level and the stock line (zero level burden)
Ironmaking Course
Blast Furnace Facilities and Cross Section
Top of the furnace

Body of the furnace
Gas Cleaner System
Drilling
Drilling Machine
Machine
Hot Stove – Cowper’s
Blast
Blast Furnace
Furnace Clay
Clay Gun
Gun
Auxiliary equipments Torpedo
Torpedo Car
Car
Slag
Slag Car
Car
Ironmaking Course
Blast Furnace Facilities
Top of the Furnace
All BFs have auxiliary equipment such as:
Conveyor belts for transporting raw
materials (iron ore and coke) to the top
of the furnace.
Hoppers for temporarily storing these
raw materials before charging.
bell-type charging equipment, where
raw materials enter the furnace through
the gap created by moving down a small
inverted bell. This bell closes and a
larger bell (big-end-down) opens to
allow material to fall into the shaft
below.
bell-less charging equipment, the raw
materials are dropped into the furnace
through a rotating chute. This device
allows charging the raw materials into
the furnace with appropriate
distribution in the radial and angular
direction.
Ironmaking Course
Blast Furnace Charging Systems
1. Parallel Hopper Bell Less Top®

• Normally 2 hoppers
• But sometimes 3 material hoppers
2. Central Feed Bell Less Top®

• Static receiving hopper
• Rotating receiving hopper
3. Compact Bell Less Top®
4. Mini Bell Less Top®
5. Bell and Double Seal Valve Top
Ironmaking Course
Series 3-parallel
3-parallel hopper
hopper Bell
Bell
Series Hopper
Hopper Top,
Top, Central
CentralFeed
Feed BLT®
BLT®with
with Central
CentralFeed
Feed BLT®
BLT®with
with RRHH
Central Less Top® (CST)
Less Top® (CST)
Central Feed
Feed Rotating Receiving Hopper
Rotating Receiving Hopper (Sollac)
(Sollac)
Compact
Compact type
type Bell
Bell Less
Less
Parallel
Parallel Hopper
Hopper Top
Top Mini
Mini Bell
Bell Less
Less Top®
Top® Top®
Top®
Ironmaking Course
Advantages of the Bell Less Top® System:
1. Burden Distribution
• More flexibility
• More Stable Operation
2. Higher Furnace Top Pressure

• Improved Furnace Operational Control
3. Reduced Maintenance
• Increased Furnace Campaign Life
• Increased Furnace Availability
4. Increased Furnace Production
Ironmaking Course
Body of the Furnace
The blast furnace has a vertical

cylindrical structure externally covered
with a shell of thick steel plate and
internally lined with refractory.
The refractory structure is cooled by
water-cooled metal components called
cooling box or staves, which are
assembled between the shell and the
refractory wall.
The furnace body is composed by
(i) the shaft, which tapers outward
from the top,
(ii) the belly, which is a straight
cylinder,
(iii) the bosh, which tapers inward
toward its bottom and is located
immediately under the belly, and
(iv) the hearth, at the bottom of the
furnace.
Ironmaking Course
Body of the Furnace
The shaft, belly, and bosh are usually

lined with chamotte brick and silicon-
carbide brick, and the hearth is lined
with carbon brick.
Depending on the size of the furnace, the
side wall of the hearth is radially fitted
with some 20 to 40 of water-cooled
copper tuyeres, which are used to inject
the hot blast into the furnace from the
hot stoves through the hot-blast main and
bustle pipes.
Tapholes for discharging hot metal and
cinder notches for discharging slag are
also installed in the hearth section.
The largest BFs at present are about 80m
in total height, with a furnace body
height of about 35m and a maximum
internal diameter of about 16m, and have
an internal volume of about 5,750 m3
which produce approximately 13,000 tons
of hot metal a day.
Ironmaking Course
Auxiliary equipments
hot stoves for heating the blast,

blowers for feeding the blast,
equipment for dust removal, and
recovering and storing the gas from the
furnace top.
Blast furnaces in which pulverized coal
is injected through the tuyeres are
provided with equipment for
pulverizing the coal and feeding it
under pressure.
In the cast house there is a drilling
machine for opening the tap hole and
the clay gun to close it when the runner
finish.
Radial probes for gas analyse and
temperature. It is assembled above the
burden and cover from wall to centre
of the furnace.
Profilometer for map the burden
distribution and measure the descend
of charge. Ironmaking Course
Blast Furnace Operation
The furnace can be charged with iron ore lumps, pellets, and/or sinter; coke and flux.
These are carried to the top of the furnace with skips or belt conveyors, and are
distributed, (not tipped) into the furnace.
At the same time, preheated air (around 1250°C) is injected through the tuyeres,
which are nozzles at the bottom of the furnace.
The coke is partially burned by the injected hot air both to produce heat, and to
generate carbon monoxide (CO). Since coke is relatively expensive, some furnaces
inject coal, tar, natural gas or oil along with the air as supplemental fuels to reduce
coke usage.
The carbon monoxide travels upward through the shaft, and removes oxygen from the
iron ores on their way down, leaving metallic iron. By the time the charge reaches the
base of the furnace, the heat generated there melts the iron. The resulting molten “hot
metal” is tapped at regular intervals by opening the “tap hole” in the bottom of the
furnace so that it can flow out.
The fluxes combine with impurities in the coke and ore to form the slag, which floats
on the hot metal and is removed through the “granulation system” (another auxiliary
equipment).
The hot metal from the furnace is collected in specially-constructed railway
containers, called “torpedo cars”. The torpedo cars carry the molten iron to the
steelmaking furnace. Ironmaking Course
Blast furnaces are operated continuously without shutdown for years (nowadays
around 20 years) or more. If the furnace were allowed to cool, thermal stresses can
cause damage to the refractory bricks.
Eventually, the refractory bricks in the furnace will wear away, and at that point
the furnace is emptied and shut down so that it can be relined with new bricks. The
period between shutdowns is referred to as a “campaign”.
Hot metal taken directly from the blast furnace contains about 94,5% of Fe, 4 -
4.5% carbon, as well as a number of other elements. This is referred to as “pig
iron” and is the mainl raw material to be converted to steel by refining in the
steelmaking process, which reduces the carbon content and removes other
impurities like (P, S , Si) to make stronger and more workable and useful product
(=steel).
Ironmaking Course
Behaviour of Different Elements in the BF Process
IRON ORE COKE

Fe2O3 MnO2 P2O5 K2O SiO2 CaO Al2O3 C S ASH
GAS
GAS
GAS
GAS
Fe3O4 Mn3O4
FeO MnO
SLAG
FeO MnO P2O5 K2O SiO2 CaO Al2O3
Fe (99%) Mn (70%) P (95%) Si (10%) PIG IRON C (12%) S (5%)
Ironmaking Course
Blast Furnace Slag
Metals are generally extracted from ores which are Typical Slag Composition
always associated with impurities, mainly oxides,
called gangue. Typical Range
During the extraction of the metal, the gangue is CaO 40% 34-42%
removed, by addition of flux, and form the slag, an
homogeneous melt (solution) of oxides, which is MgO 10% 6-12%
insoluble in the metal. SiO2 36% 28-38%
Blast furnace slag is formed from the acidic gangue Al2O3 10% 8-20%
of the metallic burden, ashes of the coke and Total 96% 96%
auxiliary injected fuels and basics fluxes as
limestone and/or dolomite.
Four major components amount to about 96% of the Definitions of Basicity
slag (CaO, SiO2, Al2O3 and MgO)
During the process, firstly a primary slag is formed B2 CaO/SiO2
during melt process and before the solution of the B3 (CaO+MgO)/SiO2
coke ash components into the slag.
(CaO+MgO)/
B4
After the the primary slag progress to a final slag. (SiO2+Al2O3)
Ironmaking Course
Blast Furnace Cross Section:
Internal view
Raw
Materials
COUNTERCURRENT Exhaustion
PROCESS Gas
Coke
Ore
Granular
Zone
Coesive
Zone
GOOD Dripping
Zone
PERMEABILITY IN
THE BED IS Tuyere
ESSENTIAL!!! Tap
Hole
Slag
Pig Iron
Hearth
Ironmaking Course
Solid Move Down and Gas
Come Up Inside the Blast
Furnace GRANULAR ZONE
ORE LAYER
GAS SOLID
hot gases cross the bed burden top charged is COKE LAYER
of coke and ore, heating heated
them and accomplish the TEMP. BEGIN
MELTING
chemical reactions of the
process. iron oxide reduction
reactions are started. COESIVE
LAYER
TEMP.
combustion of coke (C) MELTING
with pre-heated air (O2) the reduced iron oxides
produces energy to are melted. FLUXO
COKE DE GÁS SOFTENING
burden heating and & MELTING
WINDOW
reduction. ZONE
pig iron and slag are
settled in the hearth COKE
COMBUSTION
and separated by
pre-heated air (1100°C) density, from where SLAG
is injected into tuyeres. they are tapping. METAL
Ironmaking Course
Companhia
Vale do Rio Doce
IRONMAKING COURSE
REDUCTANT/FUEL TO BLAST FURNACE
August 27th 2010, Belo Horizonte, Brazil
18
Coke Production
Coke is the solid residue from destillation (progressive

heating in an air free environment) of a coal blending, in a
temperature range of 1000 ~ 1200C, in a series of thin
furnaces called coke oven.
The distillation process generates many products like
gases, condensables, benzol, tar, etc., sold by the steel
industry. The internal consumption of coke oven gas is
very important for the global energy balance of the works.
The process could last 20 hours. The incandescent product
is discharged by pushing and wet or dry quenched
The environmental aspects related to coke oven emissions
are a critical problem. A lot of units have been shut down
in the world. INCANDESCENT
COKE INSIDE
THE OVEN
Ironmaking Course
Coke Oven View
Coke Guide
Charging Car
Coke Ovem View
Drawing Machine
Ironmaking Course
Coke Oven Operations
Empty Furnace Charged Furnace
Coking Charge Leveling
Discharge
Ironmaking Course
Coke Quality Evaluation
Size Distribution
Tumble Index
CO2 Reactivity
Chemical Analysis
Ironmaking Course
Preparation of the blast furnace
burden
Components of the charge to a blast furnace:
An important aspect of the blast furnace process is the preparation of the

charge materials, in order to ensure the gas flow through the burden column.
Iron ores (hematite Fe2O3 or magnetite Fe3O4) are charged into blast furnace
in the form of lump ores, sinter and pellets. The main components of the charge
to a blast furnace are:
• Lump Ore • Pellet • Sinter • Fluxes • Coke
Lump ores:
The lump ore are naturally mined ores that are crushed and screened to a
certain grain size before their use. However, as a result of preparation and
enrichment processes in the iron ore mines to increase the Fe content, very
fine-grained ores are generated which have to undergo agglomeration before
used in blast furnace. This is done by means of pelletizing and sintering.
Ironmaking Course
burden
Components of the charge to a blast furnace:
Pellets:
Pelletizing involves the forming of ore fines (pellet feed) and concentrates with grain
sizes of well under 1 mm into pellets measuring around 10 to 15 mm in diameter. To
do this, the ore mix is moistened and a binding agent added. The "green" pellets are
then formed in rotating drums or on rotary discs . These green pellets are dried and
indurated at temperatures of more than 1000 °C. This can take place in shaft or
rotary furnaces or on a travelling grate. Pellet plants are generally located at the iron
ore producers.
Sinter:
The sintering is performed at sintering plants, measuring more than 4 m in width and
over 100 m in length. Sintering involves charging a mix of ore fines together with
coke breeze, fluxes, in-plant returns and return fines, and igniting the coke breeze
contents in the surface by means of gas flames in an ignition furnace. A stream of
gas or air is drawn from top to bottom through the mix. A flame front passes through
the thick layer over the strand length and agglomerates the mix into coarse lumps of
ore. Normally, sintering plants are located on the works sites of the steel producers.
Ironmaking Course
burden
Fluxes:
When metal is smelted, the metal is separated from its impurities by melting,
with the impurities forming a molten slag on top of the metal. Many of the
impurities associated with iron ore are difficult to melt, and so they will not
form a proper slag easily, which retards the smelting process.
To make these impurities easier to melt, fluxes are added Limestone (CaCO3)
or dolomite ((Ca,Mg)CO3) are two typical fluxes used in blast furnaces.
When a large amount of sulfur needs to be removed from the furnace charge,
limestone is the preferred flux. Limestone is also a better flux to use if slag
from the blast furnace is to be used as a raw material for cement manufacture.
An important criterion for flux selection is availability and cost, and dolomite is
often more readily available and less expensive than limestone.by gas chemical
reactions
Ironmaking Course
burden
All the iron ore charged contain oxygen, which has to be removed through
reduction in the blast furnace process. To do this, carbon is used.
The most important source of carbon is metallurgical coke, which nowadays is
produced in modern, environmentally friendly coking plants. The coke ovens,
are heated by the coking coal in coking chambers, closed off from the outside
air, in the course of which the volatile constituents such as coke oven gas, tar,
benzol, hydrogen sulphide and ammonia are expelled, collected and recycled
for other uses.
Coke:
Coke performs three main roles in a BF.

Thermal role to provide energy to heat and melt the burden;
Chemical role to act as a reducing agent and carburize pig iron.
Mechanical role to maintain the permeability;
for upward flowing gases.
for flow the liquids into hearth
OBS: Pulverized Coal Injected cannot assure permeability in blast furnace
burden. The permeable bed is provided by the coke charged to the furnace
Ironmaking Course
Mass Balance for Blast Furnace
Ironmaking Course
Carbon Consumption in the Blast Furnace
(Thyssen Stahl AG, Germany)
Basis : 400 kg C /t , Without PCI
CARBON
FUNCTION CONSUMPTION (%)
(kg/t HM)
Pig Iron Carburization 47 11,75
Reducing Gas Regeneration 100 25,00

(C + CO2 = 2CO)
Burden Sensible Heat 253 63,25

+ Thermal Losses
Total 400 100
Ironmaking Course
Main Mechanism of Fines Generation on
Ironmaking
MECHANICAL STRENGTH
Related to amount of fines generated by mechanical force
(handling)
DECREPITATION
Related to amount of fines generated by thermal shock
DEGRADATION UNDER REDUTION

Related to amount of fines generated by gas chemical reactions
Ironmaking Course
PROPERTIES OF IRON ORE AND METALLURGICAL COAL AND COKE
IRON
IRON ORE
ORE COAL
COAL // COKE
COKE
••Chemical ••Chemical
Chemicalcomposition:
composition:fixed
fixedC,
C,
Chemicalcomposition:
composition:Fe,
Fe,SiO2,
SiO2,
Chemical
Chemical Al2O3, ashes,
ashes,S,
S,PPand
andalkalis
alkalis
Al2O3,Mn,
Mn,S,S,P,
P,Alkalis
Alkalis
Properties
Properties ••Loss ••Macerals:
Macerals:Volatile
Volatilematter
matter
Lossof
ofIgnition
Ignition(LOI)
(LOI)
••Moisture ••Replacement ratio
Replacement ratio
Moisture
••Moisture
Moisture
••Size ••Size
Sizedistribution
distribution
Sizedistribution
distribution
••Average ••Mean
Meansize
size
Averagemean
meansize
size
Physical
Physical ••Porosity ••Bulk density
Bulk density
Porosity
Properties
Properties ••Mechanical ••Porosity
Porosity
Mechanicalstrength
strength
••Mechanical
Mechanicalstrength
strength
••Mineralogical
Mineralogicalcomposition
composition
••Microstructure ••Combustibility
Combustibility
Microstructure
••Crystal ••Mineralogical
Mineralogicalcomposition
composition
Metallurgical
Metallurgical Crystalsize
size
••Morphology ••Microstructure
Microstructure
And Morphology
And Thermal
Thermal ••Softening ••Crystal
Crystalsize
size
Properties Softeningand
andmelting
meltingproperties
properties
Properties ••Reduction ••Morphology
Morphology
Reduction disintegration
disintegration
properties ••Coke
CokeStrength
Strengthafter
afterReaction
Reaction
properties
••Reactivity
Reactivity
Ironmaking Course
HIGH PRODUCTIVITY ON BLAST FURNACE
MAIN
MAIN DRIVER:
DRIVER: HIGHER
HIGHER PERMEABILITY
PERMEABILITY
COKE
COKE // COAL
COAL PROPERTIES
PROPERTIES TO
TO GUARANTEE
GUARANTEE
HIGH
HIGHBLAST
BLAST FURNACE
FURNACEPERMEABILITY
PERMEABILITY
•• Physical
PhysicalProperties
Propertiesof ofthe
theCoke
Cokeand
andCoal
Coal
•• Narrow size distribution range
Narrow size distribution range
•• High
Highmechanical
mechanicalstrength.
strength.
•• Lower
Lower blast momentumin
blast momentum inraceway
raceway HIGH
HIGH
•• Lower
Lower volatile mattercoal
volatile matter coalinjection
injection
•• Metallurgical properties
Metallurgical properties
•• High
HighCoke
CokeStrength
Strength after
afterReaction
Reaction(CSR)
(CSR) PERMEABILITY
PERMEABILITY
•• Low ash content to promote lower slag
Low ash content to promote lower slag rate rate
AND
AND
PRODUCTIVITY
PRODUCTIVITY
BURDEN
BURDEN(Iron (IronOre)
Ore)PROPERTIES
PROPERTIES TO TO GUARANTEE
GUARANTEE
HIGHER BLAST FURNACE
HIGHER BLAST FURNACE PERMEABILITYPERMEABILITY BLAST
BLAST
•• Physical
PhysicalProperties
Propertiesof ofthe
theBurden
Burden
•• Narrow
Narrow size
size distribution
distribution range
range FURNACE
FURNACE
•• Good
Good mechanical strength and
mechanical strength and low
low fine
fine
•• Low
Low swelling
swelling
•• Good
Good softening
softening and
and melting
melting properties
properties
•• Low
Low reduction disintegration properties
reduction disintegration properties
•• Lower
Lower gangue to
gangue to decrease
decrease the
the slag
slag rate
rate
•• Lower
Lower lump
lump ore
ore rate;
rate; higher
higher pellet
pellet and
and sinter
sinter
Ironmaking Course
GOOD HOT METAL QUALITY AND LOW COST
MAIN
MAIN DRIVER:
DRIVER: LOWER
LOWER CONSUMPTION
CONSUMPTION AND
AND GOOD
GOOD CHEMICAL
CHEMICAL COMPOSITION
COMPOSITION
COKE
COKE AND
AND COAL
COAL PROPERTIES
PROPERTIESFOR
FOR GOOD
GOOD
QUALITY
QUALITY AND LOW PRODUCTION COST
AND LOW PRODUCTION COST
Physical
PhysicalStability
Stability
•• High
Highmechanical
mechanicalstrength
strengthandandhigh
highyield.
yield.
•• High
HIGH
HIGH HOT
HOT
HighCoke
CokeReactivity
Reactivity(CRI)
(CRI)
•• High
High replacement ratioof
replacement ratio ofthe
thecoal
coalinjection.
injection.
•• Low ash, P, and S content.
Low ash, P, and S content. METAL
METAL
•• High
HighInjection
Injectionrate
rate(PCI)
(PCI)
QUALITY
QUALITY
AND
AND LOW
LOW
METALLIC
METALLIC BURDEN
BURDEN PROPERTIES
PROPERTIES FOR
FOR GOOD
GOOD PRODUCTION
PRODUCTION
•• Physical
PhysicalProperties
Propertiesof ofthe
theBurden
Burden
COST
COST
•• Low
Lowfines
finesgenerated
generatedand
andhigh
highyield
yield
•• Low
Lowreduction
reductiondisintegration
disintegrationproperties
properties
•• Low S and
Low S and P P
•• Lower
Lower gangue,
gangue, totodecrease
decreasethe
theslag
slagrate
rate
•• Higher lump ore rate
Higher lump ore rate
**AA method
methodtotoproduce
producehigh
highreactivity
reactivityand
andstrength
strengthcoke
cokeisisbeing
beinginvestigating
investigatingby
byuse
useCa
Caas
ascatalyze
catalyzeelements
elements
Ironmaking Course
Lump Ore and Metallic Burden Evaluation
Chemical analysis
Classify ores into several grades
Decrepitation Test
Sample degradation during heating on the blast furnace
Tumbler Test ( ISO – 3271)

Fine generation due to transfer/drops and abrasion
Reduction Test (ISO 7215/JIS M8713)

Evaluate the reducibility of the sample
RDI Test (Reduction Degradation Index - ISO 4696-2)

Mechanical strength of reduced sample
MLT Test (Midrex Linder Test)

Dynamic reduction to evaluate metallization and degradation
Ironmaking Course
Ore and Metallic Burden Evaluation
Blast Furnace
Chemical Analysis 200

Decrepitation
Size Distribution 500

a Disintegration
800
Tumbler Test 900
a
1000
Reducibility
1100
a
1300 Softening
1400
a Melting And Dripping
1600
2000 Gas Gas
1400 Slag
a
1500 Liquid Metal
Ironmaking Course
REQUIRED PROPERTIES FOR BLAST FURNACE
METALLIC CHARGE
BLAST FURNACE INSIDE Requered Properties
Zone Phenomenon Sínter Pellet Ore Coke
Size Distribution
Resistance
and
Resistance Resistance Resistance
Pre-heating adherent
Granular
Reduction fines
Decrepitation
RDI Swelling CSR/CSI
RDI
Reduticibility Reactivity
Softening and
Softening Melting
High Temperature Properties
and Melting Gaseous Flow
Redistribution
Dripping
Dripping
Carburization
Raceway Combustion Melting Characteristics

Primary metal behaviour
Desulfurization
Hearth
S/M Separation
Ironmaking Course
INITIAL QUESTIONS
What do you understand as

softening and melting?
What do you understand as the

cohesive zone?
Ironmaking Course
Blast Furnace Cross PERMEABLE REGIONS
Section: Emphasis to ORE
Softening & Melting COKE
COHESIVE ZONE
Zone FUSING IRON
AND SLAG GAS
LINES
PERMEABLE
High heat consumption region, COKE SLITS
where is accomplished:
The greatest part of iron oxides
ACTIVE
reduction LOOSE-
Metal and slag melting PACKED
Boudouard reacion takes place

COKE BED
High thermal gradient region
TUYERE
High pressure drop COMPACT
Have a strong effect in the gas
distribution
CENTRE WALL
Ironmaking Course
Importance of Softening & Melting Zone
Pressure drop in
the granular zone
HIGH HIGH PCI
PRODUCTIVITY OPERATION
Distânce from tuyere level

OPERATION
Pressure drop in the
softening & melting
zone
Pressure drop
in the tuyeres
RESTRICTIONS FACTORS TO
PERMEABILITY
(15%) (70%) (15%)
ACTIONS HAS TO BE TAKEN TO 2,0 2,5 3,0 3,5 4,0

RESTORE THE BED
Pressure (BAR)
PERMEABILITY IN THIS
RESTRICTIVE CONDITIONS
Ironmaking Course
TEST SUMMARY
Softening Start Temperature Ts
Final Melting Temperature Te
∆ Temperature (Te-Ts)
Dripping Start Temperature Td
Reduction degree at 1100 °C R1100
Reduction Degree at Ts Rs
Accumulated pressure loss S value
Maximum Pressure Loss ∆ Pmax
Ironmaking Course
CORRELATION BETWEEN INDEXES AND THE BLAST FURNACE
RI
Reduction index at 900ºC
Ts200
Start of pressure drop
over 200mmH2O
R1000
Reduction index at 1000ºC
∆T
R1100 Te200-Ts200
Reduction index at 1100oC
Te200
End of pressure drop
over 200mmH2O
R1200
Reduction index at 1200oC Td
Start of dripping
of metal or slag
S(S’) value
Integration of pressure drop
with respect to temperature(or time)
Ironmaking Course
INDUSTRIAL TESTING EQUIPMENT - VALE
Upper Heater Power: 45 kW L

Maximum T: 1600°C o
a
Lower Heater Power: 55 kW
d
Maximum T: 1700°C
Heating Rate:
Upper: 5°C/min > 800°C
Lower: 10°C/min > RT
Input Gas:
N2 (22.7 NL/min)
CO ( 9.9 NL/min)
CO2 ( - NL/min)
H2 ( 1.4 NL/min)
Coke (20 mm)
Shrinkage and Pressure
Drop Measurement
Metallic
Burden (70mm)
Coke (20mm)
Ironmaking Course
TYPICAL RESULTS
Softening Melting
100,0 6000
90,0
5000
80,0 Shrinkage
Pressure Drop (mmH2O)

70,0 Pressure Drop
4000
Shrinkage (%)
60,0
50,0 3000
40,0
2000
30,0 Ts: 1243°C
Te: 1473°C
20,0 S: 59.51 kg.°C/cm2
1000
dPmax: 5419 mmH2O
10,0
Cohesive Zone
0,0 0
800 900 1000 1100 1200 1300 1400 1500 1600
Temperature (°C)
Ironmaking Course
Vale’s Technical Support to Customers
Technical Methodology
To provide solution in metallic => geo-metallurgy approach
Behaviour in
agglomeration and
metallurgic processes
Characteristics and
product quality
Ore dressing
behaviour
Variabillity and ore

types
Geological and
mineralization
processes
Ironmaking Course
Physical Simulation (1)
Lump
Steel Mills
Pig iron
Sinter Sinter
feed Steel
Sinter Plant
Pellets
Pellet BF BOF
feed
Pelletizing
Parameters
Chemical Productivity Reduction indexes

Physical Fuel consumption Cohesive zone properties
Metallurgical Product characteristics Permeability of burden
Mineralogical Interaction coke/metallic burden
Sinteriza
Sintering ção
pot
Piloto
Characterization
Pilot Plants
Pelotização
Pelletizing
Piloto pot
Metallurgical tests Softening
Forno and melting &
de Amolecimento
furnace
Chemical Analysis
Ironmaking Course
Numerical Simulation (1)
Global thermal balance
Operations covered by mathematical

models at Vale
Coke oven
Rolling
Sintering
Hot Metal
BOF
Steel
BF
Pelletizin
Casting
DRI
LUMP Direct reduction FEA
Ironmaking Course
Blast Furnace Fluid-dynamic Model
(CFD)
CFD Model considers:
¾ Fluid and solid flows
¾ Burden distribution
¾ Softening and melting of burden components
¾ Void fraction inside furnace
¾ Temperature dependence of kinetic parameters
¾ Heat and mass balances
Outputs:
¾ Different operational practices
¾ Productivity
¾ Coke rate
¾ Position and thickness of cohesive zone
¾ Operation with high PCI
Environmental aspects
63% Sínter
¾ 27% Pe lotas
10% Granulado
Ironmaking Course
Blast Furnace Fluid-dynamic Model
(CFD)
Simulation motto: “Operate a virtual Blast Furnace”
Increase production ?
Increase thermal reserve ?
reduce coke consumption?
increase PCI ?
Reduce hot metal cost ?
Unstable Stable response
Need for
model/operator
interaction
CFD Operator
Ironmaking Course
Ironmaking Course
Physical and Numerical Simulation
Steelmaking chain
Lump
PIG IRON STEEL
Sinter
SINTERING
Pellets
Sinter Feed
BF
BOF
Sintering Neural Optimization of iron ore Computational Fluid Dynamic Model BOF model
Network Model mix (linear programming)
BF inner state predictions
Numerical simulation
Mass and heat balance

Prediction of Optimum iron ore mix to of refining operations
sintering parameters minimize pig iron costs to calculate steel costs
and product and/or slag volume in BF and quality
Physical simulation
PHYSICAL SIMULATION
Pelletizing pilot plant

CVRD products
Sintering pilot plant characteristics
BF pilot plant
Characterization facilities
Ironmaking Course
Value in Use (VIU)
Concept (1)
Generation of Models
INFO Treatment Strategies

(SIMULATION)
Intelligence
Build-uo
Data Analysis
Knowledge Physical Simulation
Numeric Simulation
Organize
and Process Data Base Structure
INFO and classification
Data Mining
Operational
Data INFOrmation Generation
(Data Base)
Client
Technical Visits
Situation
Ironmaking Course
Thanks for your attention!!!
Ironmaking Course

Iron Making Course - Blast Furnace

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Iron Making Course - Blast Furnace

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Companhia

Vale do Rio Doce

August 27th 2010, Belo Horizonte, Brazil

 Metallurgical reactor where the iron

1) Definition of the blast furnace volumes

1) Total Volume: Is the volume of the BF between the bottom

 Top of the furnace

1. Parallel Hopper Bell Less Top®

2. Central Feed Bell Less Top®

3. Compact Bell Less Top®

4. Mini Bell Less Top®

5. Bell and Double Seal Valve Top

2. Higher Furnace Top Pressure

4. Increased Furnace Production

 The blast furnace has a vertical

 The shaft, belly, and bosh are usually

 hot stoves for heating the blast,

IRON ORE COKE

Fe (99%) Mn (70%) P (95%) Si (10%) PIG IRON C (12%) S (5%)

REDUCTANT/FUEL TO BLAST FURNACE

August 27th 2010, Belo Horizonte, Brazil

 Coke is the solid residue from destillation (progressive

Empty Furnace Charged Furnace

Coking Charge Leveling

Components of the charge to a blast furnace:

 An important aspect of the blast furnace process is the preparation of the

• Lump Ore • Pellet • Sinter • Fluxes • Coke

Coke performs three main roles in a BF.

Basis : 400 kg C /t , Without PCI

Pig Iron Carburization 47 11,75

Reducing Gas Regeneration 100 25,00

Burden Sensible Heat 253 63,25

Total 400 100

 DEGRADATION UNDER REDUTION

Tumbler Test ( ISO – 3271)

Reduction Test (ISO 7215/JIS M8713)

RDI Test (Reduction Degradation Index - ISO 4696-2)

MLT Test (Midrex Linder Test)

Chemical Analysis 200

Size Distribution 500

2000 Gas Gas

Zone Phenomenon Sínter Pellet Ore Coke

Raceway Combustion Melting Characteristics

What do you understand as

What do you understand as the

 Boudouard reacion takes place

Distânce from tuyere level

(15%) (70%) (15%)

ACTIONS HAS TO BE TAKEN TO 2,0 2,5 3,0 3,5 4,0

Softening Start Temperature Ts

Final Melting Temperature Te

Dripping Start Temperature Td

Reduction degree at 1100 °C R1100

Accumulated pressure loss S value

Maximum Pressure Loss ∆ Pmax

 Upper Heater Power: 45 kW L

Pressure Drop (mmH2O)

To provide solution in metallic => geo-metallurgy approach

Variabillity and ore

Chemical Productivity Reduction indexes

Operations covered by mathematical

Simulation motto: “Operate a virtual Blast Furnace”

Increase thermal reserve ?

Metallurgical reactor where the iron

Top of the furnace

The blast furnace has a vertical

The shaft, belly, and bosh are usually

hot stoves for heating the blast,

Coke is the solid residue from destillation (progressive

An important aspect of the blast furnace process is the preparation of the

DEGRADATION UNDER REDUTION

Boudouard reacion takes place

Upper Heater Power: 45 kW L