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COLLEGE
OF
ENGG
&
CERAMIC
TECHNOLOGY
PLANT REPORT
NAME:
1. SARBAJIT MANNA(11302011030)
2. NAJMUL ALAM(11302011018)
3. SUDEB CHATTERJEE(11302011036)
4. MIRZA ASIF BEG(11302011020)
5. NAZZIR HOSSAIN(11302011022)
blast
furnace
is
usually
built
with
a steel case
of
the
blast
furnace
"wind"
is
in layers.
blown
At
inside
the
same
the
time,
furnace.
Special nozzles called "tuyeres" are used to put the air in the
furnace. The nozzles are at the bottom of the furnace. This
process is called "blasting". It is why it is called a "blast
furnace". The coke ignites (= lights into fire) and burns. This
creates carbon monoxide because there is not enough oxygen
to
make carbon
dioxide.
The
carbon
monoxide
used
directly
for
steelmaking,
put
into
The gases rise up and are collected on the top of the furnace.
As the gas contains a lot of carbon monoxide, it is a valuable
fuel. The gas collected on the top of the blast furnace is
called blast furnace gas. It is then washed and dried and all
solid particles such as soot or ore dust are collected. The gas is
then burned in special ovens called Cowper stoves or hot blast
stoves into carbon dioxide. The heat from burning the blast
furnace gas is then used to pre-heat the blasting air, "wind",
which in turn is blasted into the blast furnace itself.
The slag is not waste. It can be used in various ways. It can be
made into bricks and used for construction, or it can be mixed
with concrete. Concrete which contains blast furnace slag is
stronger than ordinary concrete and is almost pure white,
where normal concrete is dirty grey.
A blast furnace can usually work for 10 to 20 years without
stopping. This is called "campaign
A blast
furnace is
type
blast
furnace,
fuel, ore,
are
so
that
the chemical
reactions take
place
from the bottom, and flue gases exiting from the top of the
furnace. The downward flow of the ore and flux in contact with
an upflow of hot, carbon monoxide-rich combustion gases is
a countercurrent exchange process.
In contrast, air furnaces (such as reverberatory furnaces) are
naturally aspirated, usually by the convection of hot gases in a
chimney flue. According to this broad definition, bloomeries for
iron, blowing houses for tin, and smelt mills for lead would be
classified as blast furnaces. However, the term has usually
been limited to those used for smelting iron ore to produce pig
iron, an intermediate material used in the production of
commercial iron and steel, and the shaft furnaces used in
combination with sinter plants in base metals smelting.[1]
[2]
the molten iron and, higher up, a slag hole to remove the
mixture of impurities and flux. The hearth and bosh are thickwalled structures lined with carbon-type refractory blocks, while
thestack is lined with high-quality fireclay brick to protect the
furnace shell. To keep these refractory materials from burning
out, plates, staves, or sprays for circulating cool water are built
into them.
The stack is kept full with alternating layers of coke, ore, and
limestone admitted at the top during continuous operation.
Coke is ignited at the bottom and burned rapidly with the
forced air from the tuyeres. The iron oxides in the ore are
chemically reduced to molten iron by carbon and carbon
monoxide from the coke. The slag formed consists of the
limestone flux, ash from the coke, and substances formed by
the reaction of impurities in the ore with the flux; it floats in a
molten state on the top of the molten iron. Hot gases rise from
the combustion zone, heating fresh material in the stack and
then passing out through ducts near the top of the furnace.
The entire furnace is lined with suitable refractory and carbon
blocks in the hearth and in the periphery of the hearth bottom.
In addition to refractory lining, there are water coolers,
designed to enhance the life of the furnaces. There is a tap hole
of suitable dimension and length for the purpose of tapping the
hot metal. The raw material at the top will be charged either
through 'double bell system' or 'bell less system' for furnace
smelting. Since blast furnace is basically a counter current
apparatus the descending stream of raw materials extract heat
from the ascending stream of gas generated from the burning
of coke at the tuyere level. The ascending stream of gas
contains CO (carbon monoxide)nitrogen and hydrogen and in
Charging sequence
To facilitate smooth working of furnaces, the coke and the non-coke
material is to be
distributed in a particular fashion in the whole circumference of the blast
furnace. For
with
introducing
greater
RACEWAY
Coke and Hydrocarbons are oxidized
Large evolution of heat
HEARTH
Saturation of Carbon with Iron
Final Reduction of P, Mn, Si and Sulphur
Reaction impurities reach their final concentrations
Falling/drop of Metal and Slag bring heat down into the Hearth
The liquid products hot metal and slag settle in the hearth.
These two products are removed periodically from the blast
furnace. The process is called tapping the blast furnace Furnace
performance is linked with the smooth operation of the furnace
which gets disturbed very often due to various kinds of
fluctuations taking place in operating parameters.
The common difficulties which are encountered in day to day
operation are :
Channeling.
Scaffolding.
Hanging.
Slipping.
Choking of Hearth.
Chilling of Hearth.
Burning of Tuyeres.
Coke rush through tap-hole.
Hot Blast Section:
Principle of operation
The Process
Iron oxides can come to the blast furnace plant in the form of
raw ore, pellets or sinter. The raw ore is removed from the earth
and sized into pieces that range from 0.5 to 1.5 inches. This ore
is either Hematite (Fe2O3) or Magnetite (Fe3O4) and the iron
content ranges from 50% to 70%. This iron rich ore can be
charged directly into a blast furnace without any further
processing. Iron ore that contains a lower iron content must be
processed or beneficiated to increase its iron content. Pellets
are produced from this lower iron content ore. This ore is
crushed and ground into a powder so the waste material called
gangue can be removed. The remaining iron-rich powder is
rolled into balls and fired in a furnace to produce strong,
marble-sized pellets that contain 60% to 65% iron. Sinter is
minutes. Generally 8 -9 41
tapings will be done in a day. The usual way of opening the tap
hole is to drill the tap hole until the skull is reached. Some
times oxygen lancing is carried out to melt the skull. Generally
the tap hole is located in such a way that after tapping
minimum amount of metal should remain in the hearth. So it is
almost at the bottom most part of the hearth. After opening the
tapping hot metal will comes out first. After some time the
liquid level
in the hearth decreases and the slag that will be floating on the
metal comes out of the tap hole.
The skimmer plate separates the slag from the metal and
diverts the slag into the
slag ladles/SGP through slag runners. The hot metal continues
to flow down the bend
runner from which it is diverted into individual metal ladles. The
control of this operation
is accomplished by cutters located in the runners or with the
help of rocking runner and
pusher car. At the end of the tapping the tap hole is closed with
the mud gun, which is
electrically or hydraulically operated
The hot metal is collected in a refractory lined vessel called hot
metal ladle and for
safety reasons it is filled up to 85-90%. Using these ladles hot
metal is transported from
blast furnace to mixers in SMS,PCM and foundry.
Similarly slag is collected in slag ladles and is dumped in the
dump post or sends to slag
granulation plants (SGPs) in which slag is granulated, and
Begins at 850 F
Fe3O4
2) Fe3O4 + CO = CO2 + 3 FeO
Begins at 1100
F
3) FeO + CO = CO2 + Fe
or
Begins at 1300
FeO + C = CO + Fe
At the same time the iron oxides are going through these
purifying reactions, they are also beginning to soften then melt
and finally trickle as liquid iron through the coke to the bottom
of the furnace.
The coke descends to the bottom of the furnace to the level
where the preheated air or hot blast enters the blast furnace.
The coke is ignited by this hot blast and immediately reacts to
generate heat as follows:
C + O2 = CO2 + Heat
Since the reaction takes place in the presence of excess carbon
at a high temperature the carbon dioxide is reduced to carbon
monoxide as follows:
CO2+ C = 2CO
The product of this reaction, carbon monoxide, is necessary to
reduce the iron ore as seen in the previous iron oxide reactions.
The limestone descends in the blast furnace and remains a
solid while going through its first reaction as follows:
CaCO3 = CaO + CO2
This reaction requires energy and starts at about 1600F. The
CaO formed from this reaction is used to remove sulfur from the
iron which is necessary before the hot metal becomes steel.
This sulfur removing reaction is:
Iron (Fe)
= 93.5 - 95.0%
Silicon (Si)
= 0.30 - 0.90%
Sulfur (S)
= 0.025 - 0.050%
Manganese (Mn)
= 0.55 - 0.75%
Phosphorus (P)
= 0.03 - 0.09%
Titanium (Ti)
= 0.02 - 0.06%
Carbon (C)
= 4.1 - 4.4%
There is an ore storage yard that can also be an ore dock where
boats and barges are unloaded. The raw materials stored in the
ore yard are raw ore, several types of pellets, sinter, limestone
or flux blend and possibly coke. These materials are transferred
to
the
"stockhouse/hiline"
(17)
complex
by
ore
bridges
the
same
job
with
an
automated
conveyor
and
distribute
the
raw
materials
evenly
around
the
Around the bottom half of the blast furnace the "casthouse" (1)
encloses the bustle pipe, tuyeres and the equipment for
"casting" the liquid iron and slag. The opening in the furnace
hearth for casting or draining the furnace is called the "iron
notch" (22). A large drill mounted on a pivoting base called the
"taphole drill" (23) swings up to the iron notch and drills a hole
through the refractory clay plug into the liquid iron. Another
opening on the furnace called the "cinder notch" (21) is used to
draw off slag or iron in emergency situations. Once the taphole
is drilled open, liquid iron and slag flow down a deep trench
called a "trough" (28). Set across and into the trough is a block
of refractory, called a "skimmer", which has a small opening
underneath it. The hot metal flows through this skimmer
opening, over the "iron dam" and down the "iron runners" (27).
Since the slag is less dense than iron, it floats on top of the
iron, down the trough, hits the skimmer and is diverted into the
"slag runners" (24). The liquid slag flows into "slag pots" (25) or
into slag pits (not shown) and the liquid iron flows into
refractory lined "ladles" (26) known as torpedo cars or sub cars
due to their shape. When the liquids in the furnace are drained
down to taphole level, some of the blast from the tuyeres
causes the taphole to spit. This signals the end of the cast, so
the "mudgun" (29) is swung into the iron notch. The mudgun
cylinder, which was previously filled with a refractory clay, is
actuated and the cylinder ram pushes clay into the iron notch
stopping the flow of liquids. When the cast is complete, the iron
ladles are taken to the steel shops for processing into steel and
the slag is taken to the slag dump where it is processed into
In the blast furnace, iron ore is melted and reduced using coke
and limestone. The materials are charged from the furnace
top to form layers. Hot blast blown from the furnace bottom
burns the coke and reduces the iron ore to produce molten
iron at the bottom. Limestone combines with impurities in the
ore to produce slag on top of the molten iron at the bottom.
Importance
of
refractories
with
characteristics
extensive
knowledge
and
experience
accumulated
Corporation
selecting
provides
the
engineering
refractory
and
materials
products,
which
are
Impact
resistance
CO gas resistance,
Alkaline resistance,
and
abrasion
Corrosion
resistance
against
against
molten
Resistance
the high
temperatures
and abrasive
often
form
undesirable
elephant
foot
shaped
Attack mechanism
Resulting damage
Abrasive wear
temperatures
fluctuations
Impact
Middle stack
Lower stack
Medium
Loss of bricks
to
heavy
temperatures fluctuations
Gas erosion
Oxidation and alkali attack
Heavy
fluctuations
Erosion by
abrasion
Spalling
temperatures
gas
jets
and
Spalling
Wear
Deterioration
Severe spalling
Wear
Belly
Bosh
Medium
temperatures
High temperature
Stress attack
Deterioration
temperatures
Spalling
Wear
Stress cracking and
wear
Temperatures fluctuations
Oxidation
and
wear
fluctuations
Abrasion
region
Spalling
fluctuations
Oxidation and alkali attack Deterioration
Abrasion, gas erosion and
Wear
high temperature
Medium
and
Tuyere
and
cracks
Raceway
Deterioration
Shell damage
(water
and
oxygen)
Slag attack and erosion
Damage from scabs
Spalling
Deterioration
Wear
Loss
of
elements
cooling
and
tuyeres
Hearth
Oxidation (water)
Zinc, slag and alkali attack
High temperature
Erosion from hot liquids
Iron notch
Heavy
Wear
Deterioration
Stress build up and
cracking
Break out risk
temperatures Spalling
(tap hole)
fluctuations
Erosion (slag and iron)
Tap hole wear
Zinc and alkali attack
Deterioration
Gas attack and oxidation Wear
and
(water)
deterioration
Selection of appropriate refractory combination depending on
the wear mechanism is very important. An improper selection
of the refractories often leads to a refractory failure which,
subsequently, becomes a complex problem to solve. Types
of refractory lining required in a blast furnace region wise as
well as the trend in the refractory lining pattern is given in the
Fig 1.
which
are
being
subjected
to
stringent
operating
conditions,
it
is
necessary
to
have
good
creep
(refractoriness
in
compression
under
load)
value
and
PCE
and
higher
RUL
(pyrometric
cone
hence,
the
only
solution
for
this
can
be
Refractory lining
system
design
The
to
CO
disintegration.
or
dense
alumina
Super
duty
brick
having
Table:
Blast
furnace refractories
Area
Present
Trend
Stack
Belly
Bosh
39 % 42 %% Al2O3
39 % 42 % Al2O3
62 % Al2O3, Mullite
Tuyere
62 % Al2O3, Mullite
Alumina-chrome
(Corundum)
Lower
hearth
Tap hole
carbon
Carbon/Graphite block
Pitch
Main trough
water
bonded
masses,
Castables
High
bonded
Ultra
low
cement
mixes,
Gunning
repairing
technique
alumina
SiC
made
with
high
temperature
electrically
calcined
through
mould press
pore,
good
alkali
resistance
and
high
thermal
manufactured
from
lower
quality
flint
mass
include
good
viscosity
and
good
sintering
the stack at an initial temperature of around 1000C and rises to the throat
reducing and heating the burden on its way. From Fig. 2, in which the Boudouard
line is superimposed on the oxide reduction equilibriums, it can be seen that a
gas consisting of 100% CO is capable of reducing the oxide to metallic iron. If the
temperature were to fall to 900C, equilibrium with FexO would be established at
70% CO + 30% CO2. The element of gas might then be supposed to come into
contact with coke and, if the temperature fell again, this time to 800C, CO would
be regenerated and its concentration is raised to 90%, so that it was again
possible to reduce FexO to metallic iron. Oscillation between the gas
compositions indicated by the two lines could continue until the temperature had
fallen to 700C, when the influence of the Boudouard would be such that no
reduction of FexO could take place, although at temperatures between 700 and
650C, reduction of Fe2O3 to FexO via Fe3O4, would still be possible. At
temperatures below 650C, hematite could be reduced to magnetite, but the
reaction rate might be expected to be slow.
below:
FeO + C = Fe + CO
Carbon reduction is thus highly endothermic and requires the combustion of
coke to make good the heat it consumes: The use of carbon as a reductant is
actually a "direct reduction", called carbon reduction (the term "Direct
Reduction" is reserved as a collective description of processes that are
alternatives to the blast furnace).
3. Gaseous vs. carbon reduction
Superficially, the endothermic nature of carbon reduction would appear to render
it unattractive in comparison to gaseous reduction, which is exothermic. The
truth however is slightly more complex.
Firstly, the CO comes from coke, and the equilibrium limitations prevent
complete combustion to CO.
Secondly, gaseous reduction yields a large thermal surplus, and by way of
contrast, though carbon reduction is associated with a thermal deficit, it uses
only one third of the amount of carbon to produce each mole of iron.
Therein lies the attraction of a combination of the two reduction mechanisms,
since some of the heat generated by gaseous reduction (or more accurately by
the combustion of coke to CO) can be used to compensate for the heat
requirements of fuel-saving carbon reduction. Both types of reaction are
therefore encountered in the blast furnace, with some 60-65% of the oxygen
originally present in the burden being removed by gaseous means and the
remainder by carbon reduction [1].
4. High temperature reactions
Reduction in the bosh and hearth is not confined to iron oxides. For example
virtually all the P2O5 contained in the burden is reduced to phosphorus, which
dissolves in the metal and must be removed in the steelmaking process that
follows. The phosphorus content of an iron ore is thus of crucial importance
in determining its commercial value, since phosphoric iron takes longer to refine
to finished steel. The normal phosphorus content of iron for the BOF is around
0.1-0.2%. Other oxides such as silica (SiO2) and manganese oxide (MnO) are
only partly reduced, with the result that silicon and manganese partition
themselves between slag and metal. A number of factors influence this process,
including slag composition and temperature. As may be deduced from the free
energy relationships appended to equations:
SiO2 + 2C = Si + 2CO: D G = +713 900 - 367.95T
MnO + C = Mn + CO: D G = +290 300 - 173.22T
increasing temperature displaces equilibrium to the right in both cases, thereby
leading to higher silicon and manganese contents in the metal. The mechanism
other oxides:
38-44% CaO, 8-10% MgO, 34-38% SiO2, 10-12% Al2O3, 0.5-1.0% MnO, 1-2% S,
0.1-0.6% K2O and <0.2% FeO.
Melting temperatures vary between 1200 and 1400C.
In general, the chemical character of an oxide slag is determined by its
composition and the various constituents are classified as either acid or basic, e.
g.
Acidic oxides: SiO2 P2O5, B2O3
Basic oxides: CaO, MgO, MnO, FeO, Na2O, K2O
Intermediate oxides: A12O3 Fe2O3
Slags high in lime are therefore basic and those of high silica content are acid.
The distinction between acids and bases is made on the grounds of their
behaviour in slag solution, since basic oxides ionise and contribute oxygen
anions to the melt, whilst acid oxides remove oxygen anions, e.g.:
CaO = Ca + O-SiO2 + 2O-- = SiO44 The degree of acidity or basicity is not easily defined since there is some
uncertainty about the way in which the intermediate oxides ionise, but it is
normal to express the composition of a slag as a simple ratio, thereby giving a
number that is called the basicity. Typical expressions are as follows:
CaO/ SiO2 ; (CaO + MgO)/ SiO2 ; (CaO + MgO)/( SiO2 + A12O3)
The values of basicity are frequently linked to the distribution of elements
between slag and metal in order to demonstrate the influence of the slag on hot
metal composition.
Blast Furnace Process Control
By improving process control of the blast furnace system operating conditions
can be optimized, hot metal quality can be improved, and energy consumption
and operatioal costs can be reduced. Modern expert process control systems
continuously monitor certain parameters in the blast furnace and by using
various process models (including burden control, burden distribution, mass and
energy balances, silicon prediction and kinetic process models) calculate and
diagnose process disturbances. They then suggest, or take, corrective actions
such as modification of the rate of reducing agents or changes to the burden
distribution (APP, 2010. p.51). Current third generation control systems allow
even further improvements than their predecessors (Worrell, et al., 2010. p.83).
ODBC).
Control
- Burden distribution
- Burden control
- Hot stoves optimization
- Blast furnace supervision
- Shaft simulation
- Tapping management
- Silicon prediction
- Temperature prediction
- Cohesive zone
- Indirect reduction
- Raceway simulation
- Flame temperature
Control
- Burden distribution
- Burden control
- Hot stoves optimization
- Blast furnace supervision
- Shaft simulation
- Tapping management
- Silicon prediction
- Temperature prediction
- Cohesive zone
- Indirect reduction
- Raceway simulation
- Flame temperature
Control
- Burden distribution
- Burden control
- Hot stoves optimization
- Blast furnace supervision
- Shaft simulation
- Tapping management
- Silicon prediction
- Temperature prediction
- Cohesive zone
- Indirect reduction
- Raceway simulation
- Flame temperature
Kinetic process simulation
Full transparency of the entire blast
furnace process is made possible using
the unique kinetic process model.
At each point of a finely meshed
coordinate grid within the furnace, key
process parameters are calculated to
enable the following:
- Determination of the burden influence
on the overall process behavior
- Simulation of the blast furnace process
under varying conditions
- Analysis of internal
blast furnace conditions
INTRODUCTION
The design methods of the analysis are the formalized tool of a
understanding of processes in the quantitative form basing on the blanket
laws of the nature. The perfection of this tool is determined by a level of
knowledge of the blanket laws and correctness of their use for the
analysis of specificity of investigated processes. The base laws for the
closed systems are the laws of preservation of weight and energy, which
use at the design analysis of blast furnace smelting assumes a solution of
Fei =1,42850,01R ;
1)
i
Fe i =-0,112670,01R ;
2)
i
Fe =R 0,01;
3)
Ri
Ca i = (CaO) (SiO 2 ) (A2 O 3 ) ;
4)
Ri
Si 2 i = (CaO) (SiO 2 ) (A2 O 3 ) ;
5)
6)
A2 3 i
Ri
(CaO) (SiO 2 ) (A2 O 3 ) ;
=
Al 2 O 3Z 0,01
(CaO) (SiO 2 ) (A2 O 3 ) ;
7) Z =
(SiO 2 CaO A2 O 3 21,4[Si])
((SiO 2 ) (CaO) ( A2 O 3 )) 2
8) (Ca) =
100;
(SiO 2 CaO A2 O 3 21,4[Si])
(Si 2 ) =
((SiO 2 ) (CaO) ( A2 O 3 )) 2
9)
100;
(A2 3 ) = (Si 2 ) = (Ca) .
10)
(2)
(3)
0,0011267 R i (%);
FeOi =
R
NFeOi =-2958,5 i ;
0,01 R i (%);
Fe=
R
NFe =100 i ;
(4)
(5)
((CaO) (SiO 2 ) ( A2 O 3 ))
Ri
CaO =
(%);
i
R
NCaOi=3,333((CaO)+(SiO2)+(A2O3)) i ;
R
SiO2i=((CaO)+(SiO2)+(A2O3)) i ;
(6)
R
NSiO2i=3,333((CaO)+(SiO2)+(A2O3)) i ;
A2O3i=CaOi=SiO2i;
NA2O3i=NCaOi=NSiO2i;
(7)
(8)
((CaO) (SiO 2 ) ( 2 O 3 ))
Z=
(%);
NZ=3,333((CaO)+(SiO2)+(A2O3)) ;
(9)
(A2O3)=(CaO)=(SiO2)=-
((CaO) (SiO 2 ) ( A2 O 3 )) 2
100 (CaO SiO 2 A2 O 3 21,4 [Si]) (%);
=
((CaO) (SiO 2 ) ( A2 O 3 )) 2
30(CaO SiO 2 A2 O 3 21,4 [Si]) =
N(aO)==N(SiO2)= N(A2O3).
(10)
=N(A2O3)(A2O3)=NZZ.
(11)
II.Fei+FeOi+Fe+CaOi+SiO2i+A2O3i+(aO)+(SiO2)+
+(A2O3)+Z=1.
(12)
N(CaO)
N(CaO)
N(CaO)
N(SiO 2 ) +(aO) N(A2 O 3 ) +(aO) NCaO i +
(aO)+(aO)
N(CaO)
N(CaO)
N(CaO)
NSiO 2 i +(aO) NA2 O 3i +(aO) NFe i +
+(aO)
N(CaO)
N(CaO)
N(CaO)
NFe i +(aO) NFe +(aO) N Z =1;
+(aO)
from
which:
(aO)=(SiO2)=(A23)=
1
3
1
1
1
1
3 N(CaO) (
)
NCaO
NFe
NFeO
NFe
N
i
i
i
Z
=
;
N(CaO)
NCaO i ;
CaOi=SiO2i=A2O3i=(aO)
N(CaO)
NFe i ;
Fe =(aO)
i
N(CaO)
NFe ;
Fe=(aO)
N(CaO)
NFe i ;
FeO =(aO)
i
N(CaO)
NZ .
Z=(aO)
(13)
(SiO2)=(SiO2)-(aO)(aO);
(14)
(A23)=(A23)-(aO)(aO);
(15)
CaOi=CaOi-aOiaOi;
(16)
SiO2i=SiO2i-aOiaOi;
(17)
A2O3i=A2O3i-aOiaOi;
(18)
Fei=Fei+FeiFei;
(19)
FeOi=FeOi-FeOiFeOi;
(20)
Fe=Fe+FeFe;
(21)
Z=Z+Z Z ;
(22)
Fe
Fe Fe )=R .
Ri(1i
Then the account of updating of makeup of components Fe i, FeOi,
(aO) repeats at first with the subsequent account on those to the
formulas and reception of final results.
where:
(23)
0,01 0,00062
1 0,01
=
;
N2=1-2--2.
Then is defined the unbalance of gasified elements referred to carbon:
100 .
=-, kg/t, or in %
(24)
V
V
1 0,01 N N 0,8 ( N N
N )
V
N2
3 gas
3 blast .
On the other hand, the runout of a dry top gas on unit of a blow makes:
V
V
)=1+0,01+0,8(N
1,867 ( d C L )
V
2
V
+N)+N+
V
V
2, 3/3;
V
V
(
)=[1+0,01+0,8(N
]: : (1-H2), 3/3;
The difference V=
V
V
-(
V
V
+N)+N+
1,867 ( d C L )
V
2
+
and ratio
V
100
V / V
(25)
0,375( )
2
=
0,375( 2 ) , kg;
1)
; =
0,005 (rel.);
0,5357 (1 )
2 =
0,5357 (1 ) , %;
2)
; 2 =
2
n 2
3)
0,01 2 (rel);
0,5357 (0,5 )
0,5357 (0,5 ) , %;
=
; =
0,01
(rel.);
2
(0,5 )
2 =
(0,5 ) , %; n 2 = 0,01 2 (rel.);
4)
; 2 =
n= 0,01 (rel.);
0,5357 ( 2 )(0,5 N )
6) =
;
0,5357 ( 2 )(0,5 N ) , (3);
=
n= 0,015 ,(rel.); [when 0]. If 0, then n=0;
0,5357 ( 2 )(0,5 N )
7) =
;
0,5357 ( 2 )(0,5 N ) , (3);
=
n= 0,015 ,(rel.); [when 0]. If 0, then n=0;
0,5357 ( 2 ) 5,6
8) =
;
0,5357 ( 2 ) 5,6 , (3);
=
n= 0,015 ,(rel.);
0,5357 ( 2 )(5,6 0,8 N 0,7 )
9) =
;
0,5357 ( 2 )(5,6 0,8 N 0,7 ) , (kg);
=
n= 0,015 ,(rel.).
(26)
++ = 1. (27)
nC
n 2
n
nC
n
n
+ ++
=1
(1+
nC
n 2
n
nC
n
n
+ ++
)=1
1
1 n (
=
1
n c 2
1
n
...
1
)
n
nC
n 2
nC
n
; =
Updating of parameters:
n 2
=.= n (all
,
,
)
()=-;
(29)
()=+ ;
(2)=2+
(30)
;
(31)
()=+ ;
(2)=2+
(32)
(33)
()=+;
(34)
()=+ ;
(35)
()=+ ;
(36)
()=+ ;
(37)
()=+.
(38)
(SiO2)=(SiO2)-(aO);
(A23)=(A23)-(aO).
(39)
For each variant of updating the account on the base design expressions
with definition of the disparity of iron-balance Fe, is carried out, then all
Fe
Fe Fe )=R .
Ri(1i
(40)
; (2)=2+
; ()=+;
()=+; ()=+.
(41)
For each variant of updating on inquiry of the user the account on the
base design expressions (partially or completely) is carried out with the
purpose of the not formalized analysis of results and choice of the most
plausible variants of entering of the corrections in the initial data. On a
base of the analysis and entering of the corrections the account on the
base design expressions is carried out.
4.2. The updating for total disparity separation under the formulas
(29) - (38) is carried out. At absence of the not formalized updating total
disparity the reference value is, at presence - residual value after
updating. The size of discrepancy of makeup of a blow to makeup of a top
gas (v
in % to quantity of gas) is on expression (25) calculated. Its
Preheater (MBP) was widely used for that purpose till last
decades of past century in many Indian
furnaces. Main drawback of MBP was limitation of Hot Blast
Temperature(HBT) which was produced around 1073K and the
maintenance cost during changing of coils when got burnt was
very high. In 1857, Cowper patented fire
Checker bricks lined stove which is now widely and
successfully used in all the furnace .The installation cost is very
high, but it can give the HBT as high as 1673K. The modern
internal combustion chamber stove is a proven high
temperature unit, which has been developed from the older,
more traditional design (Figure 9a). The high temperature
internal combustion chamber stove provides an economic
alternative to the more complex external combustion
chamber designs. Stoves of this design are suitable for
operation with dome temperatures up to 1673K and will
produce a uniform blast temperature of 1523K. The successful
Krupp Koppers design (Figure 9b) technology
which allows a maximum operating dome temperature of
1823K and uniform blast temperatures up to 1623K. The
external combustion chamber concept is particularly suited to
ultra high temperature operation combined with
large blast volumes, high combustion efficiency unit with low
CO, SOx and NOx emissions. This burner has been in service in
external combustion chamber design stoves for over thirty
years and has now been developed for use in our
internal combustion chamber stoves [39] . Stove size is clearly
dependent upon the hot blast volume required for the blast
furnace. In order to maintain acceptable levels of flue gas
velocity, combustion density and the ratio of stove
height to diameter, stove size must increase as the furnace size
increases. It has been noted in the above comments that there
are two options available for stove design one is internal and
Conclusions:
It is obvious that the technology and practice of iron making
have made remarkable strides in terms of productivity, cost,
quality and process efficiency in India since last few decades.
Development and growth of metallurgical
thermodynamics and kinetics, heat mass transfer, numerical
and computer control have contributed significantly towards
this achievement. Advance development in mineral
agglomeration to produce sinter, pellets is added the
advantage. As a result the productivity of Indian blast furnaces
has grown up upto (2.5-2.6) level, with consequent reduction in
the coke rate 260-270 kg/THM with PCI upto 250 kg/THM and
Specific energy consumption up to 5.1-5.2 GJ/THM and working
environment became safer and eco friendly to fulfill the norms
level of GOI.