The blastfurnace industry took shape as a result of the development of the blooming processthe. The basic materials used for the manufacture of pig iron are iron ore, coke, and limestone. After the development of hightemperature heating elements and widespread electrification in developed countries, new muffle furnaces quickly moved to electric designs. A muffle furnace sometimes retort furnace in historical usage is a furnace in which the subject material is isolated from the fuel and all of the products of combustion, including gases and flying ash. The process of preparing pig iron was using hot blast cupola hbc furnace which was injected with charcoal powder to improve temperature process and reduction zone in the furnace.
Smallvolume blastfurnaces the future of blastfurnace. This book includes a set of equations that accurately describe stoichiometric and enthalpy balances for the process and which are consistent with observed. Pig iron is an intermediate product of the iron industry, also known as crude iron, which is obtained by smelting iron ore in a blast furnace. The blast furnace ironmaking process had, until recently, been the unchallenged method of making hot metal on a large scale. The treatment of laterites has been a research hotspot in. Extraction of iron in a blast furnace reduction haematite o. Such alloys of iron with a carbon content of about 4. The rapid development of gasbased midrex, hyl, energiron and coalbased dryiron, iron dynamics, fastmet, fastmelt, itmk3 technologies for the direct production of iron and blastfurnaceless iron metallurgy corex, finex, hismelt, romelt in the second half of the 20th century failed to lessen the dominant role of blastfurnace smelting in extractive iron metallurgy. What is the method of production of pig iron by using a. To ensure that the production process maintains a high and stable level of quality, these materials have to be metered precisely and supplied to the blast furnace in batches. Calculation of blast furnace size is empirical in nature. Blast refers to the combustion air being forced or supplied above atmospheric pressure in a blast furnace, fuel, ores, and flux are continuously supplied through the top of the furnace, while a hot blast of air sometimes with. Input to the blast furnace for the production the pig iron required for the.
Extraction of iron in a blast furnace iron is also below carbon in the reactivity series, so therefore carbon can be used to reduce it note. A technology for adding liquid pig iron to a dsp10017 furnace has been developed, tested, and introduced commercially. The introduction of such a raw material is consistent with the production process of the blast furnace, because even during a traditional process, performed by the introduction of coke and iron ores, the metal direct reduction takes place in the lowest part of the divergent. Certain technological parameters of the steelmaking operation were.
It is the molten iron from the blast furnace, which is a. Biomass, pig iron, ironmaking, carbon footprint assessment, life cycle assessment, resource, coal, coke, blast furnace. The name pig iron is meaningless to nonfarm people, as it is a figment of the imagination of the blast furnace workersall of whom were very familiar with the keeping of pigs. The blast furnace and the manufacture of pig iron by robert forsythe. Pig iron has a very high carbon content, typically 3. Publication date 19 topics blast furnaces, castiron publisher new york, williams collection gerstein. These features allow to obtain a competitive commercial pig iron 7. India produces around 67 million tonnes of crude steel per anum out of which 57% is from the pig iron produced through the blast furnace. Now there are nearly 700 blast furnace available in world. The iron metal collects at the bottom of blast furnace and is tapped out from time to time. The production of pig iron from crushing plant waste using. In steel industries iron is produced in blast furnace by reducing iron ore iron oxide with carbon coke at temperature of 12000c to 00c. The raw materials used include ore, sinter, coke, lime and various aggregates. Raw materials in blast furnace are iron ore, metallurgical coke and suitable fluxes like dolomite, lime etc.
The majority of pig iron produced by blast furnaces undergoes further processing to reduce the carbon content. Blast furnace smelting equipment sinter plant lime kiln. Though many improvements are made in the furnace over the years, the basic operation of the furnace is the same. The use of a coalderived fuel in the iron industry was a key factor in the british industrial revolution. Life cycle assessment of steel produced in an italian.
Other composition of the pig is carbon 15%, manganese 12%, sulphar and phosphorus 12%. On the diagram below of the blast furnace, just click on the labels for a more detailed description. Use of liquid pig iron in electricarc furnaces springerlink. Pig iron is a semifinished metal produced from iron ore in a blast furnace, it contain 92% iron, high measures of carbon, can say up to 3. The most common ore of iron is called haematite ironiii oxide.
Till 1990, the blast furnace route of ironmaking had about 97% 527mt share of global iron production. Pelletizing a pellet plant contains a series of balling drums where the iron ore concentrate is formed into soft pellets, in much the same manner that one rolls a snowball, to make a pellet about the size of a marble between 14 and 12. They are formed the most significantly oxides cao, sio 2, al 2 o 3. Pig iron is produced in blast furnace by reducing iron ore with carbon monoxide indirect reduction and carbon direct reduction. In our case, the time it takes for pig iron to shift in the hearth was. A wide variety of pig iron blast furnace options are available to you, there are 21 suppliers who sells pig iron blast furnace on, mainly located in asia. The respective figures are 1400 million tonnes and 72. Production of steel and pig iron in the world and in the czech republic shows fig 1. Both limestone, to remove impurities, and some scrap steel, to act as a coolant.
The most common ore of iron is called haematite iron iii oxide. The iron ore concentrate is now mixed and ready for the pelletizing process. A study of the heat flow in the blast furnace hearth. They can be up to 60 metres 200 ft tall and 15 metres 49 ft in diameter.
Modelling and analysis of oxygen enrichment to hot stoves. Blast furnace produces hot metal liquid iron using iron ore, coke, sinter. Workers before world war i were, in almost all cases, required to have a kitchen garden, and keep cows, chickens and pigs. It is the molten iron from the blast furnace, which is a large and cylindershaped furnace charged with. Sg30 safety guideline for blast furnace ministry of steel. The hot spot phenomenon in basic oxygen furnace bof process, a manufacturing process of steel and iron and the rate of oxidation of iron. Pig iron is the product of smelting iron ore also ilmenite with a highcarbon fuel and reductant such as coke, usually with limestone as a flux. Blast furnace,blast furnace process,blast furnace application. The byproducts of blastfurnace operations include blastfurnace gas whose heat of combustion is 3. Publication date 1909 topics science publisher david williams co collection universallibrary contributor indian institute of sciences. Coke pig iron was by this time cheaper to produce than charcoal pig iron.
Pig iron and refined iron ore pellets briquetted iron can also be used, and because his t method is economic at lower volumes these operations are called mini mills. About 50 to 300 ton of molten metal can be tapped at a time in hot metal ladle. They are then used to help heat the air blast, required if blast furnace is to reach the high temperatures needed to produce molten iron. The pig iron produced by the blast furnace has a relatively high carbon content of around 4 to 5%, making it very brittle, and of limited immediate commercial use.
Feb 12, 2018 pig iron is produced in blast furnace by reducing iron ore with carbon monoxide indirect reduction and carbon direct reduction. The world leader in mbf and cbf construction is sms demag company. The direct production of iron and alternatives to the blast. The iron content of the supplied waste materials is recovered as pig iron in the. Charcoal and anthracite are also used as fuel and reductant. Pig iron produced from the blast furnace is converted into cast iron and then into steel. Apr 20, 2014 the pig iron produced by the blast furnace has a relatively high carbon content of around 4 to 5%, making it very brittle, and of limited immediate commercial use. Dec, 2016 pig iron is a semifinished metal produced from iron ore in a blast furnace, it contain 92% iron, high measures of carbon, can say up to 3. Learn more pig iron is the intermediate product of smelting iron ore. Iron and the old stone furnaces of western pennsylvania.
Blast refers to the combustion air being forced or supplied above atmospheric pressure. For the ore based ironmaking process, hot stoves are very important auxilary. The top countries of supplier is china, from which the percentage of pig iron blast furnace supply is 100% respectively. In the 5th century bc the chinese used blast furnace. The iron produced in the blast furnace is called pig iron. Pig iron is produced by smelting or iron ore in blast furnaces or by smelting ilmenite in electric furnaces. The blast furnace and the manufacture of pig iron by forsythe, robert. Regular inspection of shell temperature and provision of. A production of pig iron has been conducted from crushing plant waste. Darbys original blast furnace has been archaeologically excavated and can be seen in situ at coalbrookdale, part of the ironbridge gorge museums.
Rkef on indonesia npi nickel pig iron production published on august 27, 2015 august 27, 2015 20 likes 3 comments. Smelting equipment sinter plant pig iron blast furnace. Pig iron blast furnace route international iron metallics association. This research produces a gray pig iron that can be used in the manufacture steel. Pig iron is the intermediate product of smelting iron ore. The slag is processed and used as roadfill or railroad ballast. In his discussion of electricfurnace production of pig iron and pig steel before the engineers society of western pennsylvania, dr. Pig iron and blast furnace informational encyclopedia. The blast furnace route is the dominant route for the production of iron for steel making. To make steel, the molten pig iron from the blast furnace is poured into a basic oxygen furnace bof, where most of the remaining carbon will be removed. Blast furnace smelting equipment sinter plant lime.
A blast furnace can continuously run for four to ten years with only short stops for. The end goal is that of highlighting the steelworks main hot spots and identifying. The blast furnace and the manufacture of pig iron forsythe, robert on. The blast furnace and the manufacture of pig iron robert forsythe on. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper. If you scroll past the diagram you can read about the blast furnace process. In the experimental study, manual measurements were carried out on the outer surfaces of the furnace. Blastfurnace production the production of pig iron by the reduction smelting of iron ores or pelletized ironore concentrates in blast furnaces. With design, manufacture and installation of pig iron, ferromanganese smelting blast furnace, sinter plant, hot air stove, cip system, shaft furnace, lime kiln, etc. Publication date 19 topics blast furnaces, castiron publisher.
The coal injection rate is projected to increase from 4. Theory and practice presents theoretical, experimental, and operational evidence about the iron blast furnace as well as a mathematical description of its operation. Pig iron was known four to six centuries before the common era. Since then many other alternative processes of iron making have arisen e. By using hot blast cupola combined with charcoal powder injection, it produced pig iron with a composition of 93. The direct production of iron and alternatives to the. What is the method of production of pig iron by using a blast.
Blast furnace products and there use size of blast furnace design of blast furnace is evolved through experience. The blast furnace and the manufacture of pig iron hardcover august 11, 2015 by robert forsythe author see all 28 formats and editions hide other formats and editions. Classification of slags based on oxides from chemical analysis is evident composition of blast furnace and steel slag. The pig iron produced from the blast furnace contains 90 to 92% of iron. Production of pig iron in a blast furnace 5 these properties and is brittle both when cold and after heating. As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed.
Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. Where market size permits, some degree of product specialisation is practised. Using biomass for pig iron production archive ouverte hal. Blast furnaces are also called high ovens a blast furnace is usually built with a steel case and bricks made of magnesia inside the case. Blast furnace pig iron, containing 34% carbon, can be used to make cast iron or refined further to make steel.
Plants that use electric arc furnaces can be sited closer to the market. Blastfurnace production article about blastfurnace. Sep 29, 2010 the rapid development of gasbased midrex, hyl, energiron and coalbased dryiron, iron dynamics, fastmet, fastmelt, itmk3 technologies for the direct production of iron and blast furnace less iron metallurgy corex, finex, hismelt, romelt in the second half of the 20th century failed to lessen the dominant role of blast furnace smelting in extractive iron metallurgy. Blast refers to the combustion air being forced or supplied above atmospheric pressure in a blast furnace, fuel, ores, and flux limestone are continuously supplied through the top of the furnace, while a hot blast of air. The blast furnace and the manufacture of pig iron an elementary treatise for the use of the metallurgical student and the furnaceman this book. The technology reduces the consumption of electric power by 4455 kwhton steel to 406. This page looks at the use of the blast furnace in the extraction of iron from iron ore, and the conversion of the raw iron from the furnace into various kinds of steel. The production of pig iron highcarbon material from these blast furnaces. The basic oxygen furnace bof blast furnace pig iron, containing 34% carbon, can be used to make cast iron or refined further to make steel. The common ores of iron are both iron oxides, and these can be reduced to iron by heating them with carbon in the form of coke. Blast furnace is the metallurgical furnace used for smelting iron and steel using coal or coke as fuel. An analysis of hot spot phenomenon in bof process request pdf. The carbon is very important element in the iron which exists in iron in two forms, either in a free form as graphite or in a combined form as cementite and pearlite.