BLAST FURNACE ALKALI MANAGING

Alkali input and output is usually ignored by most Blast Furnace operators.
Symptoms of Alkali
The importance of Alkali is realized only when problems like scaffolding, scabs,
leading to furnace irregularities like hanging and slipping occur.
In normal blast furnace operations, when the coke carbon starts reacting with
CO2 resulting in the solution reaction at lower temperatures (around 1000
deg.C) reducing the Fe input in the furnace.
At high temperatures around 1000 deg.C the presence of alkali metals causes
excessive swelling of ferrous burden, especially of iron rich pellets. Such
enlargement volume leads to a soft, highly porous material without any strength
leading to compaction and breakdown.

Alkali Behavior
Sodium and Potassium exist in raw materials in form of complex
aluminosilicates and mess up with stronger basic oxides such as lime at high
temperatures where good reducing conditions are reached. This happens
mainly in the tuyere zone. The alkali compounds break according to
(K2O, Na2O)x (SiO2)y (Al2O3)z + C, CO = K, Na, K2O, Na2O + (SiO2)x (Al2O3)y

Elemental sodium and potassium as well as their oxides are volatile (they have
high vapor pressures). Therefore they move up with the ascending gas stream
and get absorbed by the down coming cooler materials like coke, ore, pallets
and sinter. Some of them also deposit on the cooler areas of the stack. The part
of the absorbed alkali is again vaporized generate a circulating load within the
furnace. The rest of it is absorbed by the slag and leaves the furnace with cast
slag. (Fig 1).

Studies have showed that alkali in the tuyere level is at least 10 times higher
than the original coke. Higher RAFT will promote decomposition of alkali
compounds and therefore it doesnt favor alkali removal. Though it is proved
that central working of the Blast furnace is the best of any operations, too
much central working will develop buildup on walls.
Entry/Exit of Alkali
Alkali enters the furnace through the Raw Material (mainly coke &
limestone) and leaves the furnace through the vapor phase into the flue
dust and the cast slag.

Typical Alkali balance

Fighting Alkali
1. Using Raw material with low alkali.
2. Lowering the basicity and temperature
3. Lower slag temperature and higher slag volume.
4. Quartzite flushing which increases the flushing power of slag.
5. Hard blowing of furnace.
6. Lowering the stock level by about 10 meters, so that Alkali leaves the
furnace through the top gas. This has to be done of close supervision
by shift managers
7. Daily matching the Alkali balance with input and output.
8. Using imported coal with low ash for making coke.
9. Low alkali limestone

..thank you