ABSTRACTS

2009 Blast Furnace Ironmaking Course

Historical Development and Principles of the Iron Blast Furnace
John Ricketts, ArcelorMittal Steel USA
The evolution of ironmaking raw materials, equipment and practices will be reviewed from
ancient Egypt to the present. The basic principles of iron making will be introduced throughout
the historical development chronology. The final result of this presentation should be a basic
understanding of the iron making process and the roots of the modern blast furnace facilities and
operation.
Blast Furnace Reactions
Wei-Kao Lu, McMaster University
Blast furnace is a tall reactor to process iron ore at ambient temperature to produce liquid iron,
with metallurgical coke and other carbonaceous materials to provide chemical reagents as well as
heat needed for the processing. Iron ore and coke are charged at the top of the furnace forming a
packed bed and move downwards by gravity. Hot reducing gas and heat are generated in the
lower part of the furnace by partial combustion of coke and injected fuels with hot blast (preheated air) to a gaseous mixture of carbon monoxide, hydrogen and nitrogen. The hot reducing
gas is forced to flow upwards by pressure gradient through the void space between solid lumps in
the packed bed to exit at the top of the furnace. The counter-current flow of solid and gaseous
streams and the extensive gas-solid contact for chemical reactions and heat transfer make blast
furnace the dominant reactor in ironmaking.
Blast furnace is a very large and tall reactor, with temperature increases from the top where ore
and coke are charged to the bottom where liquid iron and slag are removed.
Roughly the main body of blast furnace may be divided into four regions, one on top of the
other, with the fifth region where hot chemical reagent for iron ore reduction and heat are
generated tucked on the side near the bottom. One could say that blast furnace is made of five
reactors packed inside a single shell; each reactor (region) plays an important role in the whole
process. Attempt will be made to simplify the description of blast furnace reactions by discuss
main reaction in each region first, then, the whole picture and operational efficiencies.
Environment, Health & Safety Issues in Blast Furnace Ironmaking
Michael Brown, ArcelorMittal Dofasco
In this presentation, environment, health and safety issues will be addressed from the perspective
of management systems, technologies to prevent and control emissions, exposures and safety
concerns, and operating practices. The management system addresses issues such as planning,
organizing, controlling, and human resources. Control technologies include air and water
treatment systems and equipment to protect the health and safety of employees. Operating
practices are reviewed in light of the effect that abnormal operating conditions have on the
environment and the health and safety of employees in the blast furnaces.

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Blast Furnace Energy Balance and Recovery: Rules of Thumb and Other Useful
Information (Computer Game)
John Busser, Danieli Corus
Simplified mass and energy balances are outlined for the purpose of optimizing blast furnace
operations. A summary of useful blast furnace related data from numerous sources is presented.
Tuyere zone, stack and general blast furnace reactions are reviewed from an energy standpoint.
The impact of variability in blast furnace input parameters is discussed. "Rules of Thumb"
relating furnace raw material and practice changes to energy consumption are reviewed. These
principles are demonstrated through a computer simulation model "The Blast furnace Game" that
uses mass, energy, chemical and cost balances to assess means of improving the blast furnace
process.
Blast Furnace Design I
Ian F. Carmichael, BSc ARCST
Paul Wurth Group
Todays efficient blast furnace operations have evolved through developments in raw materials
preparation and quality; blast furnace design, including profile, cooling system, refractory
configuration, cast house layout and operations, improvements in equipment; the application of
automation and control systems.
This paper which is complementary to others being presented on the course, reviews the
following components and sub-systems which form the blast furnace iron making plant.

BF iron making materials flow sheet

Stock house
BF charging equipment
BF proper; design for efficient operation and long campaign life
Cast house; hot metal and slag handling with associated equipment

Blast Furnace Design II

Bob Helenbrook, JNE Consulting and Engineering.
Blast Furnace Design II covers air (blast) and gas system designs for modern blast furnace
operations. Increases in hot blast pressure and temperature during the past thirty years, together
with the need to improve operating and maintenance efficiencies, and corresponding cost
reductions, have resulted in design improvements in the air and gas system designs. The subject
will be covered in the following areas:

Functional Layout and Design of Hot and Cold Blast Systems

Hot Blast Stove and Ancillary Design

Stove Firing Optimization and Control

Stove Charging Programs

Functional Layout and Design of Gas Cleaning Systems

Optimization of Gas Cleaning System Water Usage

Top Pressure Control and Energy Recovery Turbines

Iron-Bearing Burden Materials

Marcelo Andrade, ArcelorMittal USA
Iron ore pellets, sinter, and lamp ore are the main iron-bearing burden materials used in the blast
furnace. This lecture will cover how properties of pellets and sinter affect blast furnace
performance in terms of fuel consumption, production, and campaign life. The choice between
pellets and sinter is largely a matter of mineralogy of ore and geographic location of iron ore
sources relative to the steel mill. Limestone and dolomite fluxed pellets are widely used in North
America in view of their improved metallurgical properties which significantly improve blast
furnace efficiency. Recycling of in-plant generated steel mill wastes has become an important
function of the Sintering process. Briquetting is occasionally employed for the same purpose.
Direct reduced iron (DRI) or hot briquetted iron (BBI) is used to improve productivity of the
blast furnace. Handling, economic, and technical considerations in using these unconventional
materials in the blast furnace will be covered. Pellet and sinter property needs are more stringent
for high productivity and low coke rate (due to high coal and/or natural gas injection rates at the
tuyere) blast furnace operation. An integrated system perspective, including iron production
priorities, blast furnace equipment, and raw materials, is essential for selecting optimum ironbearing burden material composition for a specific blast furnace.
Coke Production for Blast Furnace Ironmaking
Hope D. Huntington, Clark Laboratories LLC
This presentation will contrast the coke requirements for successful blast furnace operation
with requirements for the cokemaking process. In many cases these requirements conflict
with each other. Production of high quality coke necessary for efficient blast furnace
operation is limited at the coke plant by coal cost and availability, coke production
throughput, and coke battery life. The objective is to facilitate a better understanding between
ironmakers and cokemakers with the ultimate purpose of producing the lowest cost, highest
quality steel. The following topics will be covered: 1) coke properties and their importance
to the iron making process, 2) coke production and the theory of carbonization, 3) factors
affecting coke quality, battery productivity, and battery life.
Burden Distribution and Aerodynamics
Steve Yaniga, US Steel Corp.
The manner of charging raw materials to the blast furnace affects the distribution of gases that
reduce and heat the descending burden materials. The distribution of burden and gases in the
stack has a strong effect on the efficiency of gas-solid reactions and on shaft permeability. These
in turn have a large influence on furnace performance as measured by fuel rate and productivity.
In addition, burden and gas distribution have an effect on furnace lining life and hot metal
chemistry.
In this lecture the effects of raw material characteristics, charging practices, charging equipment
and furnace geometry on burden and gas distribution and furnace performance are presented.
Fundamental concepts and techniques used to physically and mathematically model burden and
gas distribution are reviewed. Practical applications of instrumentation to measure and control
burden distribution are presented. Some examples are given concerning the use of various types
of charging equipment to improve burden and gas distribution and furnace performance. Finally,
some principles are outlined for the optimization of burden and gas distribution with respect to
furnace fuel efficiency, productivity and lining wear.

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Blast Furnace Slag

John DAlessio, US Steel Canada
This paper addresses the fundamentals of blast furnace slag and its importance to the overall
blast furnace operation efficiency, stability and cost. The properties of slag melting points,
chemical composition, structure and temperature are reviewed. Slag control practices for sulfur
and alkali removal, viscosity, slag volume and operating tolerances in composition and
temperature are discussed.
Day-to-Day Blast Furnace Operations
Art Cheng, SeverStal North America, Inc.
A good day-to-day operation of a blast furnace is an essential foundation to achieving desired
performance. This lecture will review the basic ingredients required for the daily operation. It
will start with discussing the daily routine and basic control for a stable operation. Topics include
burdening, standard operating procedures, monitoring key process parameters, and statistical
process control etc. As we are competing in a dynamically changing environment, operators
must be capable of modifying their operations to suit the different objectives set by management
or the market place. We therefore will review the key parameters which affect the various
objectives, such as cost optimization, campaign extension, product quality, and customer
satisfaction in terms of quantity and delivery. How to control these parameters to achieve the
desired or compromised results will also be reviewed.
Blast Furnace Control - Measurement Data and Strategy
Dan Cascioli and Vicky Grguric, ArcelorMittal Dofasco
The most desirable blast furnace operation is achieved through the use of quality raw materials
and dependable control strategies. This offers a dilemma for operators as costs increase when
trying to satisfy both criteria. As a result, ironmakers must walk a tightrope between obtaining
adequate raw materials while ensuring their control strategy is predictive enough to eliminate
process upsets that may affect corporate profitability. This paper will deal with the measurement
systems and control strategies that are currently in use in today's blast furnace operations. It will
make special note of the financial impact of model based control strategies and the measurement
systems required to successfully operate these systems. Emphasis will also be placed on "what
makes sense" for a facility in designing and implementing a furnace control strategy. In
providing this summary, the basic fundamentals of model design and operation will also be
discussed.
Challenging Blast Furnace Operations
Fred Rorick, Rorick Inc.
Modern blast furnace operations are governed by the interpretation and application of
fundamental, scientific principles. Always, however, there was the unusual or challenging
occurrence which seemed only to be surmountable though the knowledge. guile, and good
fortune of an experienced furnace operator. Collation and analysis, over time, has provided a
database and decision-making parameters for the management of such challenges, scientifically.
This paper will be specifically address four elements of furnace shutdown (bank, gravel bank for
reline, salamander tap, and blowdown), two types of restart (from bank and from empty furnace
condition), and an additional segment on recovery from a cold furnace or chilled hearth
condition. For each case, fundamental principles, and their application, will be explained.

Blast Furnace Fuel Injection

Donald Zuke, ArcelorMittal IH
This lecture will discuss the history of blast modification used in the blast furnace. Discussions
on combustion reactions and raceway phenomena will provide the background to the concept of
replacement ratio. Examples of the replacement ratio will be given. The impact of fuel injection
on burden and gas distribution will be described. The injectants discussed will be natural gas, oil,
tar and coal.
Maintenance Improvement Strategies in an Ironmaking Facility
Ron Thomas, Arcelor Mittal Dofasco
Just as the blast furnace and blast furnace technology have evolved and developed, the
maintenance of the furnace has also evolved to keep up with the processes, the equipment that
are being used, and the desire for long campaigns at minimum cost.
The evolution of the maintenance includes several processes or work streams that work together
to form a maintenance strategy. Work Process Control, Failure Elimination, Equipment
Reliability, MRO Materials Management, and Computerized Maintenance Management System
(CMMS) implementation are some of the processes that have been developed. The
implementation of these programs is different from company to company and even site to site
within companies. These maintenance strategies have an effect on blast furnace operations,
furnace delays, operating cost, and the furnace operators. The Operators understanding of a
maintenance strategy is a necessary part of achieving a successful operation and the lowest cost
hot metal.
Ironmaking/Steelmaking Interface
Cam Howey US Steel Canada and Kerry Legeard, Tallman Bronze
The interface between Ironmaking and Steelmaking is of paramount importance to the success of
an integrated steel works. The optimization of both Ironmaking and Steelmaking is contingent
upon regular communication, interaction and understanding of each others businesses. The
business planning process addresses long term optimization and provides the framework for
operations. The hot metal specification balances the requirements between Ironmaking and
Steelmaking. Selection and location of hot metal treatment processes is influenced by hot metal
quality, process capability and product specifications. Application of synchronous manufacturing
principles provides hot metal inventory control which is fundamental to operational and process
control, and is required to meet the business plan. Opportunities to lower cost are available
through the recycling of Steelmaking by-products and wastes through the Sinter Plant and Blast
Furnace.
Floris van Laar, Allied Mineral Products, Inc
In an integrated steel mill, the blast furnace is one of the first links in the steel processing chain.
The iron making process must have a reliable performance of its refractory systems to support
good Blast Furnace availability.
This paper focuses on a range of refractories which operators could be dealing with in their work
environment.
Also equipment components, which depend on long-term stability of the refractory systems, like
the blast furnace hearth refractories, are reviewed.
The criteria in taking the proper steps for the selection of iron making refractory materials and
how is it applied, will be discussed. Finally this lecture is intended to give the operator a
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practical guideline as to which factors influence refractory performance in iron making

applications.
Casthouse Practice and Blast Furnace Casthouse Rebuild
Barry Hyde, Hatch
This presentation will attempt to impart an understanding of the principles behind casting
practice and their effect on Blast Furnace operation. The presentation will follow a path
beginning with a review of technological limitations on pre 1970 designed casthouses and
refractories. It will then be followed by explanations of present day furnace process requirements
and Blast Furnace Operator's casthouse objectives. An example of modernizing a 1960's vintage
two taphole furnace will be discussed. The discussion will follow the evolution of this
modernization including installation of tilting runners and a fugitive emission collection system
during operation, results of trough water modeling studies, and the complete revamp of both
casthouses during a reline.
European Blast Furnace Practice
Dave Collins, Corus Construction & Industrial, Scunthorpe
The past shows that Western Europe was quite often the origin for new developments. This
started in Europe in the 18th century with the Industrial Revolution and especially in Great
Britain for ironmaking by the development of the coking process by Abraham Darby. The
fundamental process route has remained substantially unchanged until the middle of the 20th
century. Then in the period following the Second World War, the strong demand for steel in
Europe to support the post-war reconstruction and the increasing social prosperity which
followed, triggered many changes in the technology and economics of iron and steel production.
In the last 30 years the activities in USA, Japan, Korea and nowadays also in China made it
difficult to maintain the technological leadership of European steel sector in the global market.
Some of the traditional steelworks disappeared due to uneconomical circumstances and today
there are remaining 30 integrated works with blast furnaces in Western Europe which
corresponds to the member works of the European Blast Furnace Committee.
This presentation will focus on the evolution of ironmaking practice in Western Europe in the
past and highlight some technological aspects:

Introduction of the development in hot metal production,

Progress of the structure of reductants and ore burden materials,

Evaluation of constructional features and equipment of the blast furnaces,

Presentation of the largest European hot metal producing companies

Further outlook for the European steel industry.

Results are based on basic hot metal only and do not consider foundry iron.
Japanese Blast Furnace Prctice
Takanobu Inada
Sumitomo Metal Industries, Ltd.
The Japanese steel industry has a long history of introducing new and innovative technologies in
the field of ironmaking. The new technologies introduced during the past ten years include
technologies to use cheaper and lower-grade raw materials and fuels, measures to prolong the
service life of blast furnaces and coke ovens, promotion of energy saving, use of wastes and
solutions to environmental problems. The lecture outlines the condition of production,
technological trends and technical development themes in ironmaking technologies.
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Future Trends in Ironmaking

Joe Poveromo, ArcelorMittal Mines Canada
The role of the blast furnace in steel production is discussed, followed by the trends in blast
furnace performance. The issues facing the blast furnace process are: external such as coke
supply and internal such as limitations on coal injection and hearth life, as influenced by
phenomena in the various furnace zones. The challenges to the blast furnace process include
both alternative steel production routes such as the integrated DRI/scrap/EAF mode and also
alternative hot metal processes. These DRI and alternative hot metal processes will be listed with
comments as to their future success.

November 17, 2008

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