Blast Furnace Process & Auxiliaries | Blast Furnace | Auxiliaries | Functions | Tech It Eze

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Today we will discuss about
 Blast furnace and its process flow.
 Blast Furnace Inputs and Outputs
 Blast Furnace Auxiliaries
Blast furnace and its process flow.
BLAST FURNACE IS A MOST EFFICIENT COUNTER CURRENT HEAT EXCHANGER
Here, BURDEN MATERIALS FLOWS DOWNWARDS AND HOT GASES FLOWS UPWARDS.
BURDEN MATERIALS ENTER FURNACE AT AMBIENT TEMPERATURE AND HOT METAL & SLAG EXITS AT one thousand five hundred degree Celsius temperature APPROXIMATELY.
WHEREAS HOT BLAST ENTERS AT eleven hundred to twelve hundred degree Celsius AND
BF GAS EXITS AT one hundred to hundred fifty degree Celsius.
In Blast furnace, there is reducing atmosphere. Carbon Monoxide & Hydrogen gas mainly acts as a reducing agent.
In Blast Furnace Iron Oxides are charged in the form of Hematite. Gradually it reduces and oxygen removed, finally Hot metal produces. Impurities or gangue materials combined with flux to form Slag.
A blast furnace serves several functions:
 Iron production: Reduces iron ore (Higher Oxide to Lower Oxide and finally Iron) to produce hot metal.
 Smelting: Smelts iron ore, coke, and limestone to produce a molten iron product.
 Chemical reactions: Facilitates chemical reactions that remove impurities and achieve desired chemical composition.
 Temperature control: Maintains high temperatures (around TWO THOUSAND °C) to facilitate smelting and chemical reactions.
 Fuel combustion: Burns fuel (coke, coal, or gas) to generate heat and reduce iron ore.
 Gas production: Produces blast furnace gas (BFG) as a byproduct, used as fuel or energy source.
 Slag formation: Forms slag, a byproduct that removes impurities and protects the furnace.
 Tapping and casting: Taps molten iron and slag from the furnace bottom and send it to SMS or casts them into pigs or ingots.
 Furnace maintenance: Allows for maintenance and repair of the furnace and its components.
 Efficient energy use: Optimizes energy efficiency by recovering heat and energy from various processes.

The blast furnace plays a crucial role in the production of iron and steel, which are essential materials for various industries, including construction, transportation, and consumer goods.

INPUTS & OUTPUTS OF BLAST FURNACE
The inputs of a blast furnace are:
 Iron bearing raw material (IBRM) – Sinter, Pellets, Iron ore, DRI : The primary source of iron.
 Coke (metallurgical coal): Acts as a reducing agent and fuel.
 Dolomite (calcium-magnesium carbonate): Flux to remove impurities and form slag.
 Manganese ore (optional): Added to produce manganese-rich pig iron.
 Quartzite (optional): Added to maintain Slag Basicity and Slag volume.
 Recycled materials (optional): Scrap iron, steel, and other metallic materials etc.
 Coal, Natural gas or fuel oil (optional): Supplemental fuel to support combustion.
 Hot Blast: Compressed Cold air heated into stoves and supplied to the furnace.
 Oxygen (optional): Injected to enhance combustion and productivity.
 Steam: injected to maintain RAFT and handling of hot furnace.
 Water: Used for cooling and dust suppression.
These inputs are combined and heated in the blast furnace to produce hot metal, which is then further refined to produce steel.
The outputs of a blast furnace are:
 Hot Metal: The primary product, (Steel grade) containing around NINETY FIVE % iron, THREE TO FIVE % carbon, ZERO POINT SIX TO ONE % Silicon, ZERO POINT ZERO FOUR TO ZERO POINT ZERO SIX % Sulphur and other impurities.
 Slag: A molten waste material containing mainly Calcium, Magnesium, Silica & Aluminum Oxides and other impurities, which is tapped from the furnace and granulated and used in various applications (e.g., cement production).
 Blast Furnace Gas (BFG): A combustible gas mixture (mainly carbon monoxide, carbon dioxide, Hydrogen and nitrogen) produced during the smelting process, used as fuel or power generation.
 Dust and Fines: Small particles of iron ore, coke, and fluxes that are carried away by the blast furnace gas and collected in Dry GCP (baghouses) or wet GCP (Scrubber & Demister).
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