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Chairman
Yasuo Omori, Research Institute of Mineral Dressing and Metallurgy,
Tohoku University
Vice-Chairman
Yasuhito Shimomura, R&D Laboratories-I, Nippon Steel Corporation
Secretarial Members
lunichiro Vagi, Research Institute of Mineral Dressing and Metallurgy,
Tohoku University
Masakazu Nakamura, R&D Laboratories-I, Nippon Steel Corporation
Tsutomu Fukushima, Technical Research Center, Nippon Kokan KK
Members
Masayoshi Amatatsu, Faculty of Engineering, The University of Tokyo
Kuninobu Ishii, Faculty of Engineering, Hokkaido University
Shinichi Inaba, Central Research Laboratory, Kobe Steel, Ltd.
Takeo Usui, Faculty of Engineering, Osaka University
Masaya Ozawa, National Research Institute for Metals
Katsuya Ono, R&D Laboratories-III, Nippon Steel Corporation
Hoichi Kuwano, Institute of Industrial Science, The University of Tokyo
Mamoru Kuwabara, Faculty of Engineering, Nagaya University
Saburo Kobayashi, Research Institute of Mineral Dressing and Metallurgy,
Tohoku University
Nobuo Sano, Faculty of Engineering, The University of Tokyo
Teruhisa Shimoda, Hasaki Research Center, Central Research Laboratories,
Sumitomo Metal Industries, Ltd.
Nobuo Tsuchiya, Technical Research Laboratories, Kawasaki Steel Corporation
Masanori Tokuda, Research Institute of Mineral Dressing and Metallurgy,
Tohoku University
Hiroaki Nishio, Technical Research Center, Nippon Kokan KK
Michiharu Hatano, Hasaki Research Center, Central Research Laboratories,
Sumitomo Metal Industries, Ltd.
Tsuyoshi Fukutake, Mizushima Works, Kawasaki Steel Corporation
Masahiro Maekawa, Central Research Laboratory, Kobe Steel, Ltd.
Akinobu Yoshizawa, Faculty of Engineering, The University of Tokyo
Advisory Members
Tasuku Fuwa, Tohoku University (Prof. Emeritus)
Mayasu Ohtani, Tohoku University
Yasuji Kawai, Kyushu University
Shinichi Kondo, Hokkaido University
Mitsuru Tate, The University of Tokyo (Prof. Emeritus)
Wataru Muchi, Nagoya University
Gyoichi Suzuki, Nippon Kokan KK
Masaaki Higuchi, Nippon Kokan KK
Tanekazu Soma, University of Tokyo
Secretariat
Kunihiro Yoshioka
Tadatoshi Koga
Kenzo Kato
Shigenobu Shimazaki
Kenichi Sato
BLAST FURNACE
PHENOMENA AND
MODELLING
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photo-
copying, recording, or otherwise, without the prior written permission of the publisher.
As ironmakers are well aware, it was only a few decades ago that the
blast furnace was viewed as a strange 'black box'. Recently, however,
various in-furnace phenomena have become the subject of serious
scientific study, largely as the result of the 'dissection' of dead furnaces,
together with the development of advanced monitoring and control
techniques. In this way, a new frontier has been opened within the
venerable domain of metallurgy. In the light of these new developments,
the Committee on Reaction within Blast Furnaces was set up in March
1977 by the Joint Society ofIron and Steel Basic Research - a cooperative
research organization of the Iron and Steel Institute of Japan (ISIJ), the
Japan Institute of Metals (JIM) and the Japan Society for the Promotion
of Science (JSPS). Consisting of twenty-six members and advisors
drawn from the fields of academia and industry, this committee
collected, discussed, and evaluated numerous papers during its five-
year commission. Particular attention was paid to the interpretation of
findings drawn from the autopsy of dead furnaces, in the context of the
live furnace state, and the correlation of data regarding cohesive zone
configuration, level, and furnace performance. The results of this
intense research activity are presented here in the hope that they will
serve not only as a source of enrichment to the professional knowledge
of researchers and operators, but also as textual material for graduate
students in the field of metallurgy. The thirty-one papers are included
within eight chapters as outlined in the following.
Chapter 1 is devoted to the detailed survey of dissected blast furnaces,
focusing on their spatial analysis: namely, their cohesive zone and its
v
vi PREFACE
Preface v
vii
viii CONTENTS
Index 621
Part I
1.1. INTRODUCTION
3
4 BLAST FURNACE PHENOMENA AND MODELLING
rSl -
• ... _-
Whe"
blowout
o
Descent
aftel walel
Quenching
16 hrs
6 hrs aller
blowol-t
When
______ dissected
5
~--- ---I~
~-t
i________ ~ ! 10
I ~ g
r----- -j ~ 15
o'"
20
"
~__ _ __ Tuyere
had been inserted into the shaft after blowout and before water
quenching. It will be seen that the descent is 0·8-1'2 m at the stock line
on blowout, while that due to water spraying is about 1 m at the stock
line, getting smaller as one goes downwards and becoming almost nil in
the lower part of the shaft. Also, judging from the bend of the pipes, this
descent was almost flat in the radial directions. In addition to the above,
substances that melted and dripped through have to be taken into
consideration. However, as the locations and times at which these
composition changes take place remain unclear, no quantitative
examination is yet possible.
During quenching the temperature rise in the shaft due to water
spraying was examined, and a 150-200 °C rise was observed depending
on the details of the spray used. I. 8 Although no actual measurements are
available for the lower part of the furnace, it is estimated that the
temperature would be lower than in the shaft.
It has been shown that the property and composition changes are
subject to a considerable extent to the influence of the water spray.
However, not all the effects are known today, so results of dissection
studies should be considered in relation to individual requirements.
-.)
00
5,
Om ttl
s:
~
5 21
Reduchon ~
Role 10,01 Scaffold
CJ 10 f;
~ 10 20 E I. tT1
= 20 30 '" ;0 '"tI
_
= 30 50
50 70 .E ::r::
tT1
""0v Sofle .. ng loy .. ' Z
;;;
15
o
gE I· a:::
~Holl:molten laye',;
v
'"
c ~
~
gr 20 o
8o
- 25 Carbon bnck tT1
Slog b
Z
Q
30
Fig. 1.2.-contd.
1.0
o
-
-0-- : Ore
~ : CoSl:e
: Ore Qnd Col.e
t:;:I
1___ : Dense loyer
..,z:;r (Mixture of Lime,
Coke and Fine Particles) §
21
Bu,dol'l :
~
Pellel 700" 1!S
l Ole!' 30"'<'1 tTl
Cole 515 ."
~Clle Ic.~ I
:I:
~
Ir"'t"r Vol
~
1 1501' )
H~(lIrit D.n ~
76.,
~
t:l
IH
S ~
o
t:l
tTl
E~ Charging S~u"nc",
N 0102+ C1 C2+ E
C2 ' lorm"d cok"
z
Cl
Idl Tsurumi 1BF lei Kawasaki 3BF
Fig. 1.2.-collld.
w
Fig, 1.2,-contd.
......
tv
-
20
m. Sl
I::(l
eb"c< ~ Qrelo..,.e'
5
~
;..
~
o
~
o
T.H. U
o tr1
r
4m 3 2 I 0
t:
Z
o
Ih) Ch ibo I BF 1,1 Amogosoki I BF
Fig. 1.2.-contd.
DISSECTION OF QUENCHED BLAST FURNACES 13
While furnaces other than those mentioned above were typical of the
medium to small blast furnaces that work on sinter, the states of their
melting zones were considerably different due to differences in the
charge distribution, top design, and at the tuyere.
Generally, the ore layers and the coke layers keep their as-charged
stratification well in descending to the melting zone in the lower part of
the furnace, where three or four ore layers are softened and fused
together before melting. This formation of the fusion, or the cohesion,
zone is again considerably different from one furnace to another, but
the inverse V axisymmetrical shape, seen in the cases of Kukioka 4 BF,I
Hirohata I BF,t Kokura 2 BF,4 and Tsurumi I BF,s appears to be typical.
When considered together with the behaviour clarified by means of
marker materials,6-s. 16 the descent and structuring behaviour of burden
in the furnace may be functionally classified as shown in Fig. 1.3.
"-=-'~+-Coheslon
zone
Combustion
zone
(1) The top part, where the layering is determined by the charging
method, burden materials, and size distribution
(2) The lumpy zone, where the individual particles of ore do not as
yet get fused together, and the coke and ore layers make an
orderly descent as stratified
14 BLAST FURNACE PHENOMENA AND MODELLING
(3) The cohesion zone, where the ore is softened, fused, and
eventually melted, the ore descending forming the cohesion zone
in accordance with the state of gas flow that is in turn determined
by the burden distribution and the position of the tuyeres
(4) The coke zone, which is situated beneath the cohesion zone and
above the core, or the conical deposit of coke known as the dead
man, serving as the coke supply source for the combustion
zone
(5) The combustion zone, which is a zone of coke burning in and
around the raceway in a swirling motion
(6) The core, which is a deposit of coke of conical shape, found in the
lower part of the coke zone, and where the descending behavior
of coke is not a continuation from above, the coke being held up
for a long time
(7) The melt bath, which is composed of the slag layer on top of the
metal layer, both filled up with coke, which is often much
coagulated near the bottom, and the bath itself filling the space
between the lower portion of the core and the hearth, the upper
surface being raised or lowered in accordance with the state of
formation of slag
observe instances where the coke layers and the ore layers did not retain
the stratification, but formed a mixed burden layer at the furnace wall.
This phenomenon is known to be due to wall trouble, I and therefore is a
variation of the basic pattern. This theory has been verified in a test
conducted with a two-dimensional model for an accident involving the
fall off of armor plates at the furnace top which had happened in the
Kukioka 4 BF furnace.
In the shaft, certain peculiar formations were seen: (i) in the Tsurumi
1 BF furnace the radial distribution of the ore layer is clearly different
between the top five or six layers and the layers beneath them, and (ii) in
the Amagasaki 1 BF the medium lump coke layer is convex at the center
presenting a mushroom-like appearance. In the former, it is suggested
that fluidization of the central portion of the coke layer occurred when
the top gas flow distribution was changing while an ore layer of lesser
gas permeability was charged. 17 From the blast volume that would give
rise to fluidization, those upper five or six charges are thought to
correspond to the time when the fluidization ceased to continue as the
gas flow was reduced. The case of the Amagasaki I BF is considered to
be similar except that here the fluidization took place in the medium
lump coke layer, which is more apt to be fluidized.
In any event, these features should be regarded as peculiar to the
stockline, or the furnace top portion, suggesting the importance of blast
volume in the formation of stratification structure at the top, along with
the more obvious influence of charging apparatus and property of the
raw materials.
120mmr/)
E
* S * * : Blinded tuyere
Fig. 1.4. Tuyere diameters of Kokura 2 BF.
Coke zone
Cohesion
zone -1'~~I
Centrol
core
- Melt both
(4) The residence time of the hearth coke, as estimated from the
graphitization degree of coke at the hearth, was about 1 week (Chiba
1 BF).16
Even though the peculiar phenomenon that the cohesion zone itself
had descended was seen in Kawasaki 2 BF and in Amagasaki 1 BF, it
may be concluded from these results that the descent of materials below
the deposition slope is not continuous from above but intermittent, and
that the motion is so sluggish that residence there is for 1-3 weeks.
In fact, there is further evidence to support this theory of intermittent
descent of the core materials. An examination showed that the shell at
the lower part of the raceway which was in contact with the core
descended stratified/ and this is considered to be a result of heaving, or
Kawasaki I Tsurumi
3 BF . 1 BF I
~ \ I
~
t F\e
~~.II • I
I
~G,
~~ I
Marker
Coke
Loyers
TL
Fig. 1.6. Distribution of caged samples and marker coke layers inside the
furnace.
DISSECTION OF QUENCHED BLAST FURNACES 19
of
Mark
up-and-down, motion that the core coke was making owing to the
difference in buoyancy exerted by the tapping and accumulating
periods of hot metal and slag. 19 Further examination of the mechanism
of this motion is left to a later section but, in short, the driving force of
descent is due, partially at least, to the intermittent carburization of
metal by coke that accompanies change of slag level, and to the
consumption of coke on direct reduction by the dripping slag.
Another probable cause of coke motion is the pushing-up of core
coke under increasing buoyancy due to accumulating slag, in which the
coke tends to ascend floating along the raceway at the periphery. This is
suggested by two observations: (i) the thin lime layers found in the
Tsurumi 1 BF furnace core coke zone were horizontal at the central part
of the core lower part, turning upwards at the periphery; (ii) there was a
coke zone of slightly different nature between the shell around the
raceway (to be described later) and the core, and there coke particles of
different color, namely those coke particles that were impregnated with
slag, were occasionally found.
Finally, the upper part of the raceway where the rate of inflow of
burning coke and the gas velocity are both large should be under a
smaller load than the central part of the furnace, and consequently the
ascent of coke from below should be easy. However, this problem is still
under active discussion as no conclusive evidence has been revealed in
the dissection studies.
20 BLAST FURNACE PHENOMENA AND MODELLING
1.4.2. Formation of Shell and Movements at the Lower Part ofthe Raceway
The formation of the shell found in the Tsurumi I BF is depicted in
Fig. 1.9. It was formed starting from slightly above the tuyere center
plane to a thickness of 30-60 mm with, as mentioned above, small to
fine coke, slag of high basicity and high alumina content, and metal.
From the distribution of these substances, densification presumably
proceeded first with the coke particles closing together, then with the
viscous slag clogging the gaps between the particles. The fact that the
slag has a high basicity (high alumina content was the same for the
Kawasaki 3 BF, which operated on a mostly sinter charge, as for
Tsurumi 1 BF, for which the charge was mostly lump ores) would
appear to indicate that generation of SiO and inflow of lime in the
raceway was considerable. The features of the raceway lower part may
be summarized as follows.
(1) Traces of shell were often found stratified in the raceway lower
part, and the compositions ofthe slag in them were much the same in all
the cases. It may be that this stratified descent is due to changes in the
tuyere front state caused by the tapping slag, a phenomenon that is quite
often observed in small and medium size blast furnaces (Fig.l.lO).
(2) Many dark coke particles having numerous depressions on the
surface (those described as 'pockmarked') were found between the shell
and the wall of the raceway lower part. This was thought to show that the
metal and slag that drip down through this part have a different
o
Cil
r:n
~
::l
o
z
o"rI
10
~
(j
::r:
tTl
o
I:C
I : Co .... ty ~
II : Lorge brown round.sh cot.e ~
lit : Small brown round,s" c:olo.e "rI
1\ : Dork dM~ loyer hnt;t;lura of groph,re. meloi $Iog and C
5moll cokel
: Lorge coke .to line co~e 1· ,5 mml
\'1 : Oork ongulor lo rge co!.; •. tl'lelo; ond 5109 drop,"
\"11 : lO'g8 brown co!.:.e
~III : Dark small co'l.a, metal al'ld stag drop!
~
tTl
r:n
IX : Brown middle size colte Impregnoted with slog
\ : B.rown and dor!.:. large co~e
'V
101 Ibl
Slog
Co e
A.r-...,----'bIc-+_ Void
Melol
r"·
CO"'~'o'"
90 __ ___
,,,",,,
-0~ ~ I \
~~e
- 80 • _0
c:!' I " 50_
o c 30
'" '"
:> :>
c
10
S
~~ 20
Melol -16
~ 0
10 Slag
0» C A
=I 7
large i Mot"
Coke
SmollL
Fig. 1.9. State of shell structure around the combustion zone (Tsurumi I BF).
1 Inside of roceway
2 The shell. a moxlure of
small coke and droplets
of melol and slog
MOlly medium size coke.
loosely pocked as a whole
4~ 1 Troces of shell
composition from that of the core, and that the movement of coke in this
part of the furnace is very sluggish.
As the behavior of materials in and around the raceway appears to be
related to the discontinuous movement in the core, discussed earlier, as
well as to the dynamics of coke consumption, further research is called
for.
1.4.3. Conditions Inside the Furnace and the Shape of the Raceway
As the asymmetrical distribution of burden found in the Chiba 1 BF
and the peripheral unevenness found in the Kokura 2 BF were
considered as being due to peripheral uneven distribution of gas flow,
the relation between these phenomena and the blast volume of
individual tuyeres has been examined.
It is known that in the Kokura 2 BF the tuyere nozzles at a certain
orientation were intentionally narrowed to protect the furnace wall. 4
The blast volume for each tuyere was calculated using the Wagstaff
formula 20 from actually measured values of raceway depth, particle size
in front of the tuyere, and tuyere nozzle diameter. This is shown in Table
1.2. It will be seen that in the north-south direction, in which the small
diameter tuyeres were deployed, the blast volume was as low as 1/3 to 1/5
of that in the other directions, a fact that was considered to have caused
the cohesion zone to descend as far down as the tuyere leve1. 4
TABLE l.2
Blast Volumes Estimated for Individual Tuyeres of Kokura 2 BF
Hirohata I BF 1. V charging with bell; 1. Descent of 0 and C layers 1. Promotion of center flow by
formation of center flow as stratified high tapping rate
by in-flow of large lumps 2. Decrease of slope as they 2. Cohesion zone is sharp
2. Promotion of center flow by descend inverse V; skirt in all
CO~ mixed charging 3. Core coke movement is orientations disappearing
3. 0 layers and C layers perfectly sluggish by melting high above
stratifying tuyere level
Kukioka 4 BF 1. V charging by bell but 1. Descent as stratified except 1. Low fuel rate; normal tapping
CC~OO~ type; much in-flow mixed layer at periphery rate; presence of periphery
of ores to center, suppressing 2. In certain directions, mixed layer making cohesion
somewhat the center flow periphery flow dominated, zone W shape
2. Because of accidental helping center cohesion zone 2. Improved gas utilization rate
fall off of armor plate, O-C to extend to lower part of by coexistence of central
mixed layers developed at furnace flow and periphery flow
periphery, promoting 3. Cohesion zone disappearing
formation of periphery flows before tuyere level reached
3. No discontinuity in ore layers
to the furnace center
Kawasaki 4 BF 1. CC~OO~ charging by bell, but 1. Descent as stratified all the 1. Low fuel rate and normal
flat gas distribution intended way through tapping rate intended; flattish
by making use of armor gas flow distribution
plates
(continued)
TABLE 1.3-contd. N
0\
N
-J
28 BLAST FURNACE PHENOMENA AND MODELLING
lumpy zone and the cohesion zone, (iii) the conditions in the
combustion zone, and (iv) the state of coke inflow at the combustion
zone. This is illustrated in Fig. 1.11; it can be seen that the factors have a
cause-and-effect relationship with each other, so individual examination
can be problematical. For the sake of simplicity, if one singles out the
two factors of (a) the distribution of charge and (b) the production rate,
which is in proportion to the blast volume, their relationship with the
shape of the cohesion zone may be summarized as shown in Fig. 1.12.
Here the ordinate, the ore/coke distribution index (O/C), is the weight
ratio for the Kawasaki 2, 3, and 4 BFs and the Tsurumi 1 BF,
the layer thickness ratios of ore and coke layers as averaged over the top
five or six layers for the Chiba 1 BF, Amagasaki 1 BF, Kukioka 4 BF,
and Hirohata 1 BFs, and the layer thickness ratio as averaged over five
layers right above the cohesion zone for the Kokura 2 BF.
Distribution control
Properties of burden
Fig. 1.11. Interrelations among operation variables and resultant shape of the
cohesion zone.
u ;~L ____
Q t:I
1.5
til
Vi
m
0 n
>-l
"Eo (3
? Z
Q)
o'TI
~
g' I:)
Q. c:::
Q m
0 Z
r
n
::r:
~ m
t:I
I:C
2.0
" "
~
>-l
I L~J r~;l
..' 4 :: u
Note: o
o
In Ore Co~e ratios
]
10 Ci: 1$ bv v\leighl 2
o C . IS bv lo\er thickness I
m
Sror:E' ~~: I Asvmmetricol shope rille to mixing W shope due to 1111::<'ln9 of center Inverse V V shope with flat gas flow due to
I
Vi
of cenler riow Inverse VI Gild and periphery flows due to center periphery flow
perlpher, flow flow
N
Fig. 1.12. Relations between the shape of cohesion zone and the distribution of charged materials. \C)
30 BLAST FURNACE PHENOMENA AND MODELLING
I
~
I '", 0-0 before quench
:-"
I \ ~
tTl
E
·0 .~ '"t:I
g ::c:
I .. ~ tTl
:';
·0 Z
~ 15.0 o
.c
o ~IDg a:::
I 'im~ .c~~~~~
.a3:cr
•• Co-<) K~O TFe
o-a RD before quenching ~
I 20.0 ..... Tecrp _ ~ after water quench
~ No~O'T.Fe
bution in coke increases from 1000°C 1000°C zone and attains peak in coke, increases fast from 900°C tT1
n
zone, and that in ores attains middle to lower part of cohesion zone, reaches maximum at 1100- ::l
peak in cohesion zone just before zone, below which it gets 1200°C, then decreases rapidly. o
melting (Fig. 1.14). Thence alkali distributed between metal and This means that peak position is
z
o'Tj
in slag droplets decreases. In slag. Distribution corresponds, in lower part of lumpy zone and
coke, on the other hand, concen- like alkalis, to shape of cohesion in upper part of cohesion zone. D
tration peak at slightly lower zone, suggesting gaseous S Relationship with gas flow iiiz
position than for ores, then originated from below (Figs 1.18 unclear in that there were n
decreases in combustion zone. and 1.19). On the other hand, two instances in central flow type ::c:
tT1
However, there were cases where types of behavior found for S in furnaces where middle to Ij
concentration was high even at coke: in one it decreases as periphery parts were richer in Zn I:I:l
furnace center (Hirohata I BF burden descends (Hirohata I BF, (Hirohata I BF, Amagasaki 1 BF).
and others). Maximum content of Tsurumi I BF, Kawasaki 2 BF, This is because circulation region ~...,
alkalis per se found in cohesion and others); in the other it of Zn is different from those of
zone lower part, and distribution reaches maximum slightly below alkalis and S (Figs 1.23 and 1.24)
corresponds well to shape of cohesion zone as in Kokura I BF
zone. Therefore it is surmised (Fig. 1.20)
tT1
[Jl
that ascending gaseous alkalis
originate in combustion or
I
dripping zone (Fig. 1.15)
(continued)
w
w
w
.j:>.
TABLE 1.4-contd.
ttl
Alkalis Sulfur Zinc'
E
...,
Circula- From lOOO°C zone down to From lOOO°C zone to tuyere level From middle part of lumpy zone ;:g
tion region tuyere level of 900-1250°C to cohesion zone
~
Paths of Reduction-gasification from slag Gasification on combustion of Direct sublimation or reduction- ~
ascent droplets trickling through coke in combustion zone (COS, gasification at 1200-1250°C, and tTl
dripping zone and that from HsS, CS~, and ascent on gas ascent on bosh gas "tl
::r.:
coke burning in combustion stream generated in combustion
zone, as well as by gas stream zone ~
upwards from combustion zone
o
a::
into furnace interior
Amount of l3-24 kg-(Na20 + K20)/ton-hot 0'4-2'7 kg-S/ton-hot metal 5,2-6 kg/Zn/ton-hot metal in ~
circulation metal (Table 1.5 and Fig. 1.17) (Figs 1.21 and l.22), though Amagasaki I SF; 6' 5-7' 5 kg in ~
depends much on S content in Tsurumi I BF t:I
coke 8
Difference Basic sinter < acidic pellet Acidic pellet < basic sinter, Not much difference among ores, t:I
tTl
in absorp- (Fig. 1.16), though in Amagasaki though in Amagasaki I BF the though generally ores are more t""
t""
tion by ore 1 BF it was MgO-bearing MgO-bearing pellets were less effective than coke Z
pellet < lump ore < sinter effective q
DISSECTION OF QUENCHED BLAST FURNACES 35
TABLE 1.5
Estimated Circulating Alkalis
Furnace
Hirohata I BF 13-1
Kawasaki 2 BF 19'5
Kawasaki 3 BF 16'5
Tsurumi I BF 24
Kokura 2 BF 17-18
Amagasaki I BF 22-23
5~-'~--------------------~
Ore Slag
o • Periphery
o 6 A Middle
C • Center
] 10
C
-"
u
o
1;;
C
E
g 15 C
i-'"
-Si
o
20 o
Fig. 1.14. Changes in alkali contents in ores and slags in blast furnace
(Tsurumi IBF).
W
0\
Na , O + K, O 1%1 NO lO + K, O 1%1
~ <0 .1 >2%
0 01 - 04 III
1.5- 2
• >0.4
1-1.5 §
Belore <I 'Tl
charging 0. 7 C
~
f;
t'I'l
"C
:I:
t'I'l
Z
~t'I'l
~
~
o
6
I:)
t'I'l
E
z
Cl
101 In the slag Ibl In the ores lei In the coke
0.5
g>
.~
'"
t
0 : Middle K2 Kawasaki 2BF
K3 Kawasaki 3BF
:!! 0.4
0 : Periphery
Tl Tsurumi 1 BF
-"
u Sinter
0 KK2 Kokura 2BF
10
Acidic A1 Amagasaki 1 BF
E
g 0.3 pellets
.9
~ill K2
. .\ ----ll..
0
0:; 0.2
L1 \
u
." ~O \SR
ill
KK2 \SP ,
E
a
is 0.1 !) \ "
I~
" A1
z I \ Tl
, if 6,
K3
0
0 0.01 0.02 003 0.04 0.05
IK 2 0 + Na201 IT Fe
ITsurumi 1 Bfl
SjT.fe lin acid pellell
o 0.0004 0.001
o t
Ji
a;
,t t
CL IKawasaki 3 Bfl
,
1t ! JACid pellel
,
5 SjTfe lin sinterl
00004 0001 ~ I S,nler
50
I : Metal drop
E
n s: ~
~~
(j)
~10 E ~ C'- a
~ if 0-
D
in ': r0-
10 C'-
ro
~
u
E
o ~ .~:
..:= 15 E \ b
l'
(j)
u 15
c
.~ B
o c
20 ~
o
20 6
Tuyere level
Fig. 1.18. Changes in S contents of ores and metal in blast furnaces (Tsurumi
1 BF and Kawasaki 3 BF).
DISSECTION OF QUENCHED BLAST FURNACES 39
•• ••
~ < 10 ~ <005 ~ 0.01 - 0.05
•
~ 1.0- 1.5 0.05-0.10 0.05-0 10
> 1.5 >0.10 >0.10
0.9
.
So ,,, CO!1"bU5t,O'" Torol S
g 08 fudu@'
•
~_ 07
gZ I
.
.•
0.6 "
0
~@ 0.5 "."
~! 0.4 0'
g~ 0.3
_ 0.2
• ••
"".. ~
.
~
£ 0.1 ".
H, 0,0 •
-0,1
03 04 05 0, I 0,2 03 04 05 0 I 02 03 04 05 06 07
TOlol S 1%1 Tolol S 1%1 S 10 ,,1
" e:,w"J"
Tsurumi I BF Unit: [kg·S THMI Kawasaki 3 BF
lumpy
I ""
zone
l L _]34
-0.62 -075
Cohesion
zone
2.92 ~r
04~ 0.49 Met,l [SI/S =8.0
25 Ui
1.25- -;
~ (1~0
1,14
. 618 Slag 210 kg
125~ 0
0591 ~5t ~ ~
"
Hearth U
ISlagl IPigl [Slogl [Pigl
231 kg 274 kg
Zn 1%1
~ <001
0.01-0.1
>0.1
Before
c ho(g ing 0.006
(2) The lumpy ores have mostly been thermally cracked or worn to
pulverized form, only a small portion of them retaining the original
form, just as in the case of sinter.
(3) The pellets, both acidic and basic, on the other hand, mostly
remained in the original form, regaining the strength after having been
reduced to about 40 kg/pellet once. 10. 22
(4) The degree of reduction is inordinately low before the start of
softening-melting, clearly indicating re-oxidation having ocurred, so
much so that no differences were seen due to the type of ore.
In short, no particularly novel insights were gained into property
changes of ores in the lumpy zone. For this, investigation of the shaft of
a live blast furnace by sinking probes will be more fruitful.
With regard to the cohesion zone lower part, on the other hand, the
entire process, starting with cohesion of several pieces of ore,
DISSECTION OF QUENCHED BLAST FURNACES 43
A ... : Zn
o • :S
13.5 c • :K
120
] 10.5
~
~9.0
2
E 7.5
o
.,
.!: 6.0
~ 4.5
g
o.~ 3.0 "--
1.5
O L--L~ __~-L__L-~~~~~
800 1000 1200 0 0 I K 100102
Temperature I·CI I I I
T,urum i I B.f
7 {), @
8 @
9 @
Fig. 1.25. Results of X-ray diffraction analysis for lime (Tsurumi IBF).
44 BLAST FURNACE PHENOMENA AND MODELLING
I /-
i1IT/ /~Y []
l1Lb/;/ J 13
(
Sinter\
70%) []
'0
I '0 ---14
[]
T-l : Tsurumi I BF
t
- M
":':L 15 K-3: Kawasaki 3 BF
Fig. 1.26. Effects of burden materials on the development of the cohesion zone.
TABLE 1.6-contd.
.j::.
-...)
.j::>.
00
ttl
TABLE l.7-contd.
~>-l
Structural characteristics X-ray diffraction
analysis of veins
~
Cohesion 1. Structure is undergoing great change: mixed phases of slag and metallic iron, ~,y-2CaO . Si02 ~
m
zone where slag is the seeped out slag at the periphery or the dark to transparent 2CaO . AlP3 . Sial
(1200- ones in the interior, are seen :r:""m
1300°C) 2. Phase containing dark slag is compositionally close to 2CaO· Si0 2 containing Z
Contrac- little Al 20 3, and is thought to have been derived from the acicular calcium
o
~
tion 30-50% ferrite; that containing transparent slag is of a 2CaO . Al 20 3 . Si02 containing
much Al 20 3, and is thought to have derived from massive calcium ferrite
~
;..
3. Slag at periphery is of low basicity and high alkali composition
~
Half- 1. Both metallic iron and slag conglomerated into large particles tl
molten 2. Many iron particles contain slag globulets, at which interfaces high ~
zone concentration of Ca and Mg is detected o
tl
(~ 1350°C) m
t""
t:
z
Q
DISSECTION OF QUENCHED BLAST FURNACES 49
~ 80
c;-
c 60
0
Q
~
u
u 40
0
0
QJ
;,0 20
3.0
/,c-., '-0
, "
0"" \
,,
c:r' \ AI
'b___ · o ____o
r
~ 75
>-
u
c
0
"-
50
"
u
u
0
0
<))
4: 25
.c 1.5
~
1:'
;;; 1.0
~
~
'"
a< 0.5
,c
.';: Q.) 2c
<)).c <))
D- "-
U
0 -0- -
10 '"
.~ CD
'"" 0V
o ~
20 LV
.=
"
!" ..
0-"
~ 30 'iJ -
00..5
c
,Q 0
U 40 • Sinle,.
~ v • MgO pellet
;:
8 50
0
• Acidic pellet
'0
'" 60
"
C<
70
80
90
Fig. 1.29. Softening under load cuIVes of specimens sampled in the furnace in
comparison with their before-charging counterparts (Kawasaki 3 BF).
shell is formed assisted by the low melting phase, and this shell is strong
enough to hold the pellet for a while.
This theory is supported by comparison of changes in high
temperature reduction rates between the cases with alkalis and those
without alkalis, shown in Fig. 1.30. However, even for acidic ores, if the
Al 20JSi0 2 ratio is small, i.e. if the alumina content is small, formation
of Al20 3 • K20 . 2Si02 and low melting phase is promoted, so the
softening can be hindered.
2.0 r - r - - , - - - - r - - , - - - - - r - - - ,
u
Sl
~
~ 1.0 1.0
o
0<
<I
I
U O~----,~-_+--~-_+~O
Sl
~
1000 1400
~
o R.Dl: Before charging
~-1.0 RD2: Taken in the furnace - 1.0
Fig. 1.30. Changes in the difference of high temperature reduction rate (RD)
between specimens sampled in the furnace and their before-charging counter-
parts (Tsurumi 1 BF).
the amount and composition of gangue (for acidic pellets especially the
Alz0 3/Si0 2 ratio, and for basic sinter the basicity and the MgO content)
with alkali contained.
6 .-~---r--,---"ro--~---r--.---r--.---r--,
Sinter 0.546 >
Ore 01,/. 0.057
5 0
Coke 0.051
Coke 0.038
t"
:] 4
°
l
0;
>
2 3 ." "W:"",
\'>,11 ,
. ,, ""
~
. ,\ 0
\61 ..
~ ~ a;
::: "'0 c:
"0 4 0 ' :
o .- QJo
~ -~· U - -"'-. ~\~!?. ~I~ - - - - -
"'~.O,D
t 1+
I
r-
Drop 01 .,~
i I
t~ ?
2 I
Massive
i
0.3 0.4 05 03 04 05
CoO IS,02 CoO j AI,O" + MgOJ
E
g
..::! 0
o
v;
0-1
2
Finol topping slog
0.4 o.~
~
.!1 3
..
~
>- 2
2
E
g
..
u
c
0
0
6- 1
- 2
- 3
0.1 0.2 0.3 0.1
• 0.2 0.3
Fig.1.31-contd.
AI,O J Iwl%1
Fig. 1.32. Relations between composition of gangue in the charge and changes
in composition of slag.
TABLE 1.8
Major Factors Contributing to Formation of Slag
Mainly sinter Acidic ores + Lime
Formation of (1) Separation and (1) Formation of acidic
dripping slag in dripping off of low slag out of reaction of
the zone basicity, low melting silicate slag and lime,
phase out of high and of lime phase
basicity, high that has reacted with
melting phase slag somewhat
(2) Radial composition
changes due to
segregated
distribution of lime
Assimilation reaction (3) Reaction of dripping slag with high melting
of two phases phase that descends carried by metal and coke
Effects of combustion
zone
motion (4) Inflow of unmelted high melting phase into
temperature combustion zone
(5) Promotion of melting of unmolten phase by
prevailing high temperature
reaction (6) Reduction of Sial and generation of SiO
combustion (7) Separation and scattering of coke ash
Tsurumi 1 BF Kawasaki 3 BF
Sinter IB=;o 18016090
Acidic pellet 70%
lime
Gangue
Olivine ICoO)
I zone
Center
I Tuyere I
level
I Center
RocElvay
I Coke
Final slog
I ash
CoO,"SiOc
---J OT
---l eN
~ ,~H
'''' ...
--'
I
Fig. 1.34. Compositional changes of droplets of metal and slag (Hirohata I BF)_
.
• woU ~Ide
.& M~ddl8 porr
• C~nler pOfl t::owosoh:3 BF
- Mo
E 3 ! 18 C
;:: 2 ;:t; 19
_~ I a20
'" 21
~ 0 ~2'2
~ - I ~13
6 - 2 0
ConCenlrQI,on ~
huruml I SF
] S E 18 C
- - 19
E ~ 20
1 2 g 21
~ 0 ~ 22
c g23
C_ 1 0 24
O ~I~2~
~ 3 ~'~O~O'~O~
. 1~1~~~O~'C~a~I~
1 ~O~O~I~O~O~
~ ~O~
~
ConCf;!nllo tIOt'J '\.
• ..... ,
...... "
• 6 Tuyefe \
12 Te~pero r ure or
IS· Ct\ \\~ .. \
~ , '
Alomlt~ \ ... \
'quid surfoce
1700'C
'1~
10 '. rOllo \ \ \ \ \ ~ 16QO'C
E
~\\'''.~ I500'C
1 8 "~ 1400'C
II gO ->--<~. ..,,~ ,-,
0
;;
6 H/
+n l
.;;
6
.'{~
", 'If \:\\~,:\
"::.\
-05
'--"'Ii
(f.~~' .' , .~~...
2
. .
'\
,"\
\ '\ \
\,'
'\
'\
. "'.
101 0 I 2 3
C 1"'01
• 2
S,
4
tOot
6 Ibl
0
0 6
C 10.0 1
1.10. ADDENDUM
The foregoing was compiled from data obtained before June 1979. Since
then, the Nagoya 1 furnace 25 - 27 and the Kakogawa I furnace 28 - 3o were
blown out, and dissection results have partially been published. The
pertinent data and the in-furnace arrangements of these two furnaces
are shown in Table 1.9 and Figs 1.37 and 1.38.
TABLE 1.9
Data on Dissected Blast Furnaces (Supplement)
Nagoya 1 BF Kakogawa 1 BF
TH Side
Fig. 1.37. Inside arrangements of dissected blast furnace (Nagoya IBF, 2nd).
w N
OT
1 BF was reversed for the upper and the lower parts. For this, the
information of reduced blast should be considered. In the same furnace,
further, a layer of fine particles that contained metal and slag was found
to exist at the boundary between the core coke of the dripping zone and
the overlying layer of coke that was flowing into the combustion zone.
As the presence of a similar layer was detected in other furnaces also,
this observation should be considered as revealing a phenomenon
important for analyzing the gas flows and other movements in the
vicinity of the central core.
(2) Little disintegration was seen in the pellets, but cracks developed
concentrically, and the decrease in strength was considerable.
(3) The reduction rate was not the same in the radial direction even
within a single ore layer, the reduction progressing fast suddenly in the
vicinity of the cohesion zone.
(4) In the cohesion zone, there was unreduced FeO remaining at the
center, and this tendency was stronger for acidic pellet.
It will be noted that these observations are basically the same as those
obtained through water quenching. However, the significance of the
Nagoya I BF is that it has substantiated the conclusions drawn from the
results obtained on the water sprayed samples. The reports on alkalis,
zinc, sulfur, and others as unaffected by water are awaited.
REFERENCES
64
MEASUREMENTS IN OPERATING BLAST FURNACES 65
have exerted upon the operation of the furnace. This has led us to
believe that, if samples are taken of the burden during furnace
operations, they will provide a clue to enable burden properties to be
improved. Accordingly, blast furnace instrumentation now includes
sampling of the furnace burden.
sounding
rod
top gas temp.,
pressure, composition
furnace top probe
Itemp, gas compn.1
Furnace Charge Gas temp. Gas flow" Charge Hot spot Mechan- fJ-wave
~c::
top profile distribu- tracing profile monito- ical profile g;
and temp. tion by He measure- ring by profile meter ~
distribu- (Kobe) (NKK) ment camera measure- (Chiba)
tion (Chiba, (Chiba, ment
Furnace Gas flow" ~
(Muroran, Kawasaki) Kawasaki) (Chiba)
top probe by He Z
NSC) o
system Gas tracer '1:l
Gas (Kokura, velocity (NKK) ttl
velocity Sumitomo) distribu-
distribu-
tion
G fl w"
as. 0
tion S
Z
(NKK) Q
(SumitomotracHmg c;,
'by e
Charge (Hirohata, §
profile NSC)
and gas
compn.
distribu-
tion ttl
CJ)
(Chiba,
Kawasaki)
I
(continued)
~
0\
00
TABLE 2.l-contd.
to
1973 1974 1975 1976 1977 1978 1979 1980 1981
~
>-l
Upper Horizontal Horizontal Gas temp. Furnace Horizontal
shaft probe probe near wall analysis fixed ~
(Kimitsu, (NSC) (SOmm) by upper probe ~
NSC) (Waka- and lower (Sakai, 1:;
yama) horizontal NSC) tTl
probe "tI
::r:
(Kimitsu,
NSC) ~
0
Horizontal E:::
tTl
probe Z
;..
(SL-IO,
11.7 m) ~
(Mizu- t:I
shima, E:::
0
Oita) t:I
tTl
Sampling t"'"
(SL-IO.7 m)
t:
Z
(Kobe) Cl
raceway ....,
etc.) Z
(Sumitomo) (Kimitsu) Raceway
observa- 0
'"C
tion by m
high-
speed ~
Z
camera 0
(Kimitsu) ttl
t"'"
>
[Il
...,
(continued)
"r1
c:::
~
(")
m
[Il
96
-.J
o
t:l:l
TABLE 2.I-contd.
~...,
1973 1974 1975 1976 1977 1978 1979 1980 1981
21
N.A
c w c w C w C W C
Furnace Furnace
wall center
Fig. 2.2. The relation between the dissected shape of the cohesive zone and the
top gas data during furnace operation.
cohesive zone
dropping zone
TE
<D
1
'"
tuyere
tuyere
tap hole
• center
o middle
5~~~~~~~~~~~~~~~~
o 1 2 3 4 5 6 7 8 9 10 II 12 13 14 15
time Ihrsl
25f--_--1
No. FR Si
CD 460 40 20
(2) 490 50 E
~\
G) 540
Q)
60
~
Q; 15
.~
E .,
\\
0
Co 10
..c
OJ \
1! \
.~
5
0
,~
\ I I I
2.4 2.5 2.6 2] \ 3.6 3] 3.8
pressure at the shaft
wall Ikg/em')
in the lower portion of the furnace increases. Thus it was found that the
height of the cohesive zone shows a good correspondence with the
change in shaft pressure.
2.3.2.2. Use of measuring devices together with estimation models for the
cohesive zone
In blast furnace operations, a knowledge of the shape and position of
the cohesive zone is vital but, in the absence of thoroughly satisfactory
direct measuring methods, a variety of estimation methods have been
tried. For routine control of the furnace, the behavior of the cohesive
zone as calculated by an estimation model is used as reference data.
The basic concept which guides the building of estimation models is
founded on the following two factors:
(1) As it flows through the cohesive zone, the hot reducing gas that
rises from the raceway will affect the furnace walls by its pressure
and temperature.
(2) The geometry of the cohesive zone will change the temperature
distribution and composition distribution of the top gas.
To make more accurate estimates, furnace walls have recently been
provided with measuring elements, or shaft probes have been employed.
The major estimation models that have been developed so far include
the following.
(a) Static pressure model. Developed by Sugata et al.,s this model is
designed to estimate the shape of the cohesive zone from the vertical
distribution of the static pressures that are measured by measuring
holes provided at positions up the furnace walls. Chapter 3 describes
this static pressure model in detail.
(b) Stave temperature model. Irita et al. 6 investigated the shape of the
cohesive zone and the changes in its shape in a MuroraN Works blast
furnace. As is clear from Fig. 2.8, the variations in the vertical
temperature distribution, as obtained from the cooling staves in the
furnace walls, is found to be in good agreement with the movement of
the shape of the cohesive zone, as calculated by the estimation model. In
short, movement of that area of the cohesive zone which is adjacent to
the furnace walls causes the heat loads on cooling staves to change,
thereby making it possible to estimate the form of the cohesive zone.
This method is intriguing in that existing detection devices can be used.
(c) Model based on gas temperature distribution and gas composition
distribution measurements. Shigemi et aU constructed a model in which
78 BLAST FURNACE PHENOMENA AND MODELLING
w (Z!
1~-~
w
o
"
1
13\
12
10
9
131 \
12
10
9
13)
12
11
10
9
13) 12
11
10
9
8 8 8 8
7 7 7 7
6 6 6 6
5 5 5 5
Fig. 2.8. Relation between the shape of the cohesive zone and the distribution
of stave temperature. 6
A SWING VALVE
B LANCE DRIVING DEVICE
C SOUNDING DEVICE
I A CLOSED CASE
Cr~!\f~=m~~~~~-~;-~-~g~b
t,\, LOCAL CONTROL
, PANEL
:,:""
0 I 2 3 4m
por
r;-WAITI NG
ION
x.y
RECORDER
If ~y.
\' icc
wa
m ~
q: ~
center of
MEASURING EXAMPLE
furnace
I
r----------sL~Om--------~
~~, I /-
~~'~'~---SL=lm---~~'7"~-~
.....:-: - .,. I /::.... /
1--------'''''''',...,,~,- SL~. 2;t>',,4::''-'"''''""'------\
coke "":::' ore
MA 4 notch
MA 3 notch
MA 2 notch
meos;uring stroke
1---- -7000----1
] 5
~
OJ
c
"D
4
0
:"
Q; 3
Q)
E
-'"
~ 2
Q. A
~
0 I
';
g
E
2 3 4 5
measured values 1m)
o: data obtained during insertion
D. : data obtained during withdrawal
Beam I
Scanner
Burden surface
Z
Sl = El + 36698 - 1000
0000 - - - - ,- - - - -"I - - - - - ~ -- --
I
I
I I ,
E -1000 - - - - -+ - - - - - - - - - - --T'---=---
I I f
.§
! : / :
-WOJ
:::; -2000
, ,.-,1/ ''
u
o I
__ J_--
1_1---'I
- - - - - - 1 - - - - , - , - - - - - - - r-----
II
Vi
I
I , I
-3000 --- - - .----- T------r----
, I I
I
detect.ng elements
Rodlol mognelOMtUer
C lfcumferenuol mognerome1er
INOla II *
TOP .. ---Throot D iameter
[ SOP ... -- Shoft D~omeler Probe
prObe]
SWP·· --- Shalt Wall Probe
ore and coke. Normal shaft probes measure intermittently, whereas the
SDP is capable of continuous measurement. Since 1975 these probes
have been installed on the Sakai No.2 blast furnace. The behavior of the
cohesive zone has since been calculated using both measured values
from these probes and the aforesaid mathematical model built for the
estimation of the cohesive zone geometry. Figure 2.16 shows the
4.0
'\
""
"" -
'0
>-_ 3.0
u >-
c 0
-<>
5>--
~ ~ 2.0
11
0
10
I x 10- 2 % I
--
68
-...
.-
66
64
ISil 62 • -;-. ~ ,........,
60
58 I'--
56
Sl814 15 16 17 18 19 20
Distance of the top end of the root
from the stock line Iml
Fig. 2.16. The relation between the top end of the root, Si contents, and the
frequency of slips.9
84 BLAST FURNACE PHENOMENA AND MODELLING
relationship between the position ofthe cohesive zone and blast furnace
operation. Figure 2.17 depicts the calculated shape of the cohesive zone
and the corresponding pattern of gas flow. This measuring system has
made the control of blast furnace operations possible.
i-I
- 2 3 4 5 6 Sl
~co
1%)
500 'C" --' V--
2
) - - - )-
BOO 50 1\
~ct \
I ~ V
<;
~
I
" 600 40
V 7""
700 'C~
l'i--.
Q.
E
,,
10 2! ,
/
I
SDP
~
12 0 400 30
rn
I
L!-V
14
~
16
18
0
20 2
c
V
f\
-'" 09
~
22
V
.~
~
24 0-
f\
w
O.B
ill
26 <;
3
07
Inner volume m3 2797
Pig iron
productivity
tiD m3 130
0
~
3 0
2.0
V
Fuel rate
t:,P/V
kg/T
-
441 10,1 2BI
0.279
'"U1~~
-
o 0
GO >-~
~
:.:::: E
1.0 '-..., /
o l)-
0
uQ)
~
Fig. 2.17. Calculated shape of the cohesive zone and the corresponding pattern
of gas flow. 9
(b) Lower shaft probe. In order to obtain information from the lower
shaft, i.e. from near the cohesive zone, Oita Works, 10 Nippon Steel, has
recently provided its blast furnaces with a mini-probe (mini-shaft
probe) at a point 12 m below the stockline. Measuring tests are still
going on to study blast furnace reactions.
Figures 2.18 and 2.19 show the state of mini-probe mounting and
examples of measured data. As is evident from the illustration,
depending on furnace operation, the mini-probe can reach a part of the
MEASUREMENTS IN OPERATING BLAST FURNACES 85
7.1 m
mini-probe in the middle ,hoft
IDEGI 1%1
1100
I I 1/
1000 mini -probe measu red ~ 70
te mperature ~
17
900 60
It I~ 1/
800
17 50
/ 1'\ V c
700
V 40 <;
Q
~ 1\ r'< 17.."
~~ f\ ~ini-probe
<; meosurt i 30 ~
iii 600
CL
E ~.
gas uti l i z~tion V ~
0
0>
2 500 ~co
20
~ 10
0
~
1\ shait ~robe u
'"
0
0>
400 \ ~co
17
300
-; 0
K ./
200
1-'\ /
sha ft probe f- /
100 t~ m~e r~ t urre
~ 1/
/
0
V
8 7 6 5 4 3 2 I 0
Fig. 2.19. Example of the data measured by the mini-probe in the middle shaft
ofOita No.2 blast furnace (around 13 :30,7 May, 1980).10
86 BLAST FURNACE PHENOMENA AND MODELLING
600
400
200
Fig. 2.20. Patterns of mean gas temperature and ffias utilization in periods L II
and III, respectively.
position of weight
before measurement gas seal
pushing rod
10
I
\~middle
b) An example of measurement
Fig. 2.22. Apparatus for sampling from tuyere, and its specification. 13
II)
v
Sample A Iproductivity 2.08 tid . m'! II)
"(;0 v
c
II)
0. O~OO~~~~~8~Q~ ~
0. 0
II)
..c <: ;g'o'~i::.!1~!1.~c ~'l;tYo a.
u ~Bc: . 0.
80 74"l ,15~ <:
g~ .c
v
o~
60 col:e
melol g~
80
~
C
40 60
" 0. .... ......1... •Iog (; II) ~
~ 5 20 ~,~....___ ... :.t"-"'" 40 ~
>- " 0
.. "a.
Gi E 20
,- 0
"0 100 'C...;..2.7 >- " 0 fi
'~- 80 ~:::~~7r""":;:
38~-~.:.r5~-:;;::: SO- 38~ c 100
.Q 80 Ul
,g~ 60 SOmm 25 - 15 15 - 10 10 - 5 :;-
-;;;
" 40 ,g~ 60 z
~o .!i ~
40
20 ~ <3g5-3
" u 20
o"tI
0 0
II)
~o " ...v tIl
i'! .~ -- 0
~ "'0 ~
2000 30 -; 0>
\1)- !; _ 2000
-5iii '0 .s ~
a. . ~ U + '0 0 1
E " • 20 "
Z
.! ,,~ 1600 -0u ~ .§ 0 1600 1: Cl
,,0» 8 O:l
G) -£ .! ~~~
~ g> ~ 1200 10 ~ "1? ~ 1200 [;
11)--
~.2 ~
"-'0_ o '"I ~ ~~ ~
o 1.0 2.0
o '"I
Distonce from Ihe tip of tuyere [m!
~~~ Distance from the lip of tuyere Iml ;:J
[oj Exomple of Ihe size distribution and amount fbi Example of the si ze distribUlion ond amount
of coke in the sompling pipe ot high of coke in the sompling pipe 01 low
productivity.
productivity.
~
tIl
r:n
00
1.0
90 BLAST FURNACE PHENOMENA AND MODELLING
"-"-. ,'x)(\
• 1.2-1.6
• 1,8-2.2
~ 4 \\{ "de> 1J151 fcom I,y"•
\. ',' 8
.a
3
\... " \ Z ","
'<~::::::t::.:-·~
...
20' - 2
::i ...... .
1.4 1.6 1.8 2.0 2.2
'~'-:_J
, ---
Productivity It/d·m 3 )
Distance from the lip of luyere
oj Relation between the productivity of the furnace
and the mean size of coke sampled at luyere level. Q 0.6-0 8m
• 1.2-1.6
.1.8-22
85r-------------------~
Distance from the tip of luyere
m
~ 00.6-0.8
m
~
.
X 1.2-1.6
~ 80 .1.8-22
o
U
75
Fig. 2.24. The relation between the furnace productivity and the properties of
sampled cokeY.
CRT
Monlior
Wriling pen
camero
~
~ .....: t------'
NOle2:
Colculolion of Hard copy
Ihe rolio of while
Two color
momtor
area / block area
Fig. 2.25. Measurement system for coke size and volume rate in raceway. 14
vertical probe
sounding rod
top gas temp.,
furnace top probe
~ pressure, c~mposition
._---( burden profile meter
\ thermoviewer
gas static. ____ -;
layer thickness meter
pressure ~_
zone, i.e. the movement of the cohesive zone near the furnace
wall.
(3) A device to determine the behavior of molten pig iron and
molten slag in the hearth.
(4) A method to measure gas velocity.
(5) A method to measure the distribution of burden layers more
accurately.
Moreover, as soon as these methods are developed, it will be equally
important to establish their commercial application as practical
measuring instruments for blast furnace control.
REFERENCES
1. Private communication: from the construction design chart of Nippon
Steers blast furnace in 1969.
2. Blast Furnace Phenomena and Their Analysis. Interim report from the joint
research committee of Iron & Steel Institute of Japan, Japan Institute of
Metals and Japan Society for Promotion of Science (1979), Iron & Steel
Institute of Japan.
3. Y. Shimomura, K Kushima and S. Arino, Tetsu-to-Hagane. 62(1967), S65.
4. T. Fukushima, H. Yamada, T. Kobayashi, Y. Niwa, T. Furukawa and
B. lino, Tetsu-to-Hagane. 67(1981), S70.
5. Kimitsu Works, Nippon Steel, report to 54th Committee, Japan Soc. for the
Promotion of Sci. and Tech., No. 1456 (1978).
6. T. Irita, Y. Kanayama and K Tashiro, Tetsu-to-Hagane, 64(1978), S48.
7. A Shigemi, A Suzuki, Y. Hida and K Yamaguchi, Tetsu-to-Hagane,
64(1978), S47.
8. Kawasaki automatic burden profilemeter for blast furnace, Catalogue of
Kawasaki Steers Engineering Division.
9. T. Yamamoto, T. Masahisa, H. Kanoshima, Y. Hayashi and K Tamura,
Tetsu-to-Hagane, 67(1981), A1l7.
10. Oita Works, Nippon Steel, paper presented at March meeting (1981).
Committee for study of inside blast furnace reactions, Organization of
Joint Basic Research, ISIJ.
11. E. Schiirmann, W. Zischkale, P. Ischebeck and G. Heynert, Stahl u. Eisen,
80(1960),854.
12. A Katayama, N. Tsuchiya, K Okabe, S. Taguchi, K Okumura and
S. Tamura, Tetsu-to-Hagane. 66(1980), S682.
13. T. Nishi, H. Haraguchi, Y. Miura, T. Sakurai, K Ono and K Kanoshima,
Tetsu-to-Hagane. 66(1980), 1820.
14. K Sano, H. Nishio, T. Miyazaki, T. Ariyama and H. Yoshida, Tetsu-to-
Hagane, 63(1977), S522.
Part II
Global Formulation
97
98 BLAST FURNACE PHENOMENA AND MODELLING
Heat requirement
___ 0
o 10 5 5/10 4 kcol
r--~I----'I--'I----'--'G
I~ lbl I 1
\1
I~--+I- - - T o t a l heat requirement---f-----;--I
~~
- - -
500
2 1 I
m
"'
.D I
1
. '
\ I ~ Heal requlre7ent over 90Q"C
0
0
I 1
H C
~a. - - - -
1
1-----,1-1 ~ I
~ 1000 Consumption --L-->k-I~--+----+---I
cedel 900'C \ I
1 \
4b
I \
J ~ Requirement
1
Consumption \
I I over 1400"(
_undeI1400°C-~ I ""',
J I 'J I " B
1500 L-__-+"---'L-_-i.J:"""'-_ E
0 ____
i B i----- _~
5X104kcai
105 _IA
Heat consumptiofl Heot consumption
I - - - - - - T o l o l heat c o n s u m e d - - - - - - - I
Fig. 3.1.1. Heat requirement curve for 100 kg Thomas pig iron.!
GLOBAL FORMULATION 99
1-5 in Fig. 3.1.1 (a) represent the heat requirements for the following
process:
1. Heating up and fusion of iron
2. Heating up and fusion of slag
3. Heat for decomposition of limestone and formation of slag
4. Heat of direct reduction of iron oxide
(a) direct reduction restricted in range 900-1400DC
(b) direct reduction occurs above 1400 DC
5. Heat of reduction of MnO, Si0 2 and P20S
The overall heat requirements for the whole process were obtained by
summing each heat requirement curve illustrated by lines 1-5, which is
shown in Fig. 3.1.1 (b). The two lines in the temperature range 900-
1500 DC show the two different fashions for the reduction of iron oxide
assumed above.
The heat content ofthe gas was calculated on the assumption that the
blast at 600°C reacted with coke at 1400 DC in the tuyere zone thereby
producing a gas mixture of CO and N 2 . This meant that 1 kg carbon
reacting with air made 2·33 kg CO + 4-45 kg N2 gas. Assuming
that 83·5 kg carbon (95·6 kg coke) was required for the production of
100 kg pig iron (66·4 kg C for combustion, 13-8 kg C for direct reduction
and 3· 3 kg C for hot metal), the heat availability of the gas could be
calculated as a function of temperature. An example of the calculated
result is shown by the line URKN in Fig. 3.1.2 together with the heat
requirements of burden materials given by the line ABCD.
"~
-"
~ 500~~~--~~--+---~
c
o
o
rn IOOO~----~~+-~~--~
<D
~ 1500 t-i----~-+--+-----'>,<+_-----""""I A
Q;
a.
E
c'" 2000 L..-'_ _ _ _'-----'-----'----_ _---'---_ _- " U
2 0
Amount of heat IIO-s keal)
0 15 ~
C
ill ill E-
rn 2 ~ E 13
~
- - - J'.'
E- .2 ~
4 6 ~ ~ ~ 11 ~
~ >f-
~r-
---a 6 -
a ill ill if> 9-::-
u
(; 1
c ______Ts_T.!_ ~_1S_ ____
0
":u
~ ~
a eT
<{
E
18 :u
0
ill
20 I
0 2 4 6
8 12 14 1610 18 20
Temperature I Xl 0- 2 °el
(3.1.2)
102 BLAST FURNACE PHENOMENA AND MODELLING
0.8
..c
]' 06
Q)
] 0.4
c
Q)
E
15 0.2
OL-~~_L_L_L~_ _~
I
I
I
I
I
I
\
\
\
"- ,
""
Tuyere 0'---4--'-00------"80'-0--1--'-20-0--"16-00-2-'000
'\
zone
16.2 5
1
.-I
, '"
,-
/"
13.2 4
:.-- Reduction intensity curve Thermal and
1 chemical reserve
I
I zone
10.2 3
\
\ ,,
7.2 2
,
- --- ----
----- ---- -- .........
1\ ,,
4.4 I
lower zone with high ,;, \
,,
intensity of reduction and
solution 105s reactions ',,, -",' , " I
-- --- --------------~..:~~,-
TUYERE S -- --- 500 1000 TEMPERATURE "0 1500
5 10 % 15
Fig. 3.1.6. Reduction intensity and burden temperature estimated from the
observed temperature of gas. lO
A
.-r---------~--._~H
~
>- 2
0
Xc OC
;:
U
f--4----+-41000'C
800
600
400
The lines given by these two equations are drawn in Figure 3.1.7 as
lines L\I and L\2. qc and qg are thermodynamic constants; consequently
the line L\I has just one variable, qv, which includes blast temperature,
whereas eqn (3.1.14) contains (Yr + Ys) which are determined by the
composition of hot metal and Q, the output of heat in the elaboration
zone except the heat of reaction accompanied with direct reduction.
This equation can therefore evaluate the effects of composition and
temperature of hot metal, amount and temperature of slag, and the heat
loss in the elaboration zone on the operation result. In addition to this
the distance VE is obtained graphically as follows:
(3.1.15)
This means that the point P takes a balance between heat input
(VE X qg) and heat output (BV X qg). As summarized above, the
operation line of the blast furnace which can satisfy simultaneously
both heat and material balances is obtained as a line connecting points
Wand P. The point W is determined by the reduction equilibrium in the
shaft part and the point P is determined by the heat balance in the
elaboration zone.
This theory was applied to the analyses of fuel savings by the
injection of reducing gas into the lower part of a blast furnace under the
assumption of fIxed shaft efficiency.'4 Furthermore, favorable comparison
was made between the results obtained from the theory and those
observed for the experimental blast furnace. '5
Fe,03 13CO-2Fe+3CO,
III C 1 CO,-2CO
MnO+CO-Mn+CO,
SiOH2CO-Si 12CO,
P,Os -I 5CO-2P + 5CO,
121 C+CO,-2CO
MElTING OF IRON
FUSION OF SLAG
REDUCTION OF REMAINING
IRON OXIDES
YS;O, Ws WI' YC
yeoQ YS,
YMgO YMn
VAI 20, yp
REACTOR (]I
Fig. 3.1.9. Corresponding part of the blast furnace to the reactors and
accumulator shown in Fig. 3.1.8Y
(1), i.e. the shaft region of the blast furnace, by considering the major
chemical and physical phenomena taking place in the region. To be
more specific, the model was derived for a steady-state one-dimensional
heterogeneous moving bed system in which heat exchange and
chemical reactions occurred between the counter-current gas stream
and the solid flow of two components. Reaction rates of indirect
reduction of iron oxide and of solution-loss reaction were taken into
account. A system of six ordinary differential equations was consequently
obtained for representing the longitudinal distributions of CO and CO2,
mass flow rates of ore and carbon, and the temperatures of gas and solid
phases
dGg.co/dz = RC02 (3.1.16)
-dGs.cldz Rc (3.1.18)
-dGs.Fe2o/dz (3.1.19)
-d(GgCgTg)/dz = 6(1 - £)hgs(Tg - Ts)/dpc/J (3.1.20)
Tg , T5 I'KI
667 889 1111 1333 1556
3.1
6.1
9.3
]' 12.2
N
15.3
18.3
21.4
24.4
z=Or-------~ ~------~
E
N
differential equations. The system gives deep insight into the essential
characteristics of blast furnace operation because it can simulate
principally the behavior of thermal and oxygen exchanges as the
superimposition of several rate processes. Unfortunately this model was
developed only for the shaft region and it cannot therefore evaluate the
whole performance of the blast furnace.
Independently, a complete one-dimensional mathematical model
was developed by Muchi et al. 18- 20 which consisted of overall heat and
material balance equations giving the solid temperature at tuyere level
and the theoretical flame temperature together with nine first-order
ordinary differential equations and two algebraic equations for
computing the internal distribution of process variables. This model is
attractive because it can estimate operational results such as productivity
and fuel ratio and also longitudinal distribution of every process
variable taken into account. A detailed description ofthis model will be
given in the next section.
The earliest attempt at two-dimensional analysis of a blast furnace
GLOBAL FORMULATION 113
Case 1 - - Case 3
IAI IBI
Case 2 ---- Case 4
rs;;a
Wall Center Wall Center
~:: z;md
,,ook==1'd
1200
L '-------.
1250~ i I Z·~8 c-" 1300 ,..---,-----,--"
t 1050 i
"
900
1750 ,---,-----,----,
,,"'- .... '\
, /
\ /
1000
1150 '-----'-----''----' 3
3 rim!
rim)
- Case 3
---- Case 1 IDI ---- Case 4
V
ICI - Case 2 Wall Center
Wall Center
015c=
0.14
I Z~m~ 018 ~z~m~
0.14 "-
_ ---'
_ __ _
.L......_...>l
D
'" Z= 4
E
.§ 0.09 '----'-----'----'
"
6
~
UO.
12 - - " ........ ,
""" Z~8
0.06
0.12~Z~12
rim)
OO~ 3 2 I 0
rim)
Fig. 3.1.12. Radial distribution of gas temperature [(A) and (B)] and CO2
content of the gas [(C) and (D)] computed from two-dimensional model. 21
GLOBAL FORMULATION 115
2.8 ,......=~:::-----=-----------,
~ 2.0
c
Intermedi a te zone
.~
"g --- Ts
] 1. 0
~ Peripheral zo ne
.s
o L-J-~ __L--L~__~-C~__~~
300 500 700 900 1100 1300 1500 1700 1900 2100 2300
Tempera ture lO KI
This proposal was very attractive because it showed the possibility for
the two-dimensional process analysis of a packed bed in which a gas
stream reacted with solid particles. One of the computed results on the
gas flow obtained by Radestock and Jeschar 3 is shown in Fig. 3.1.14.
Another important characteristic of the blast furnace is the alternating
layered structure of coke and iron ore. Kuwabara and Muchi24. 25
presented a mathematical model considering the layer by layer
structure. In the model, nonuniform gas flow was approximately
analyzed from the permeability of the bed on the basis of Ergun's
equation. This model will be fully described in Section 3.3.
Mter recognition of the existence of the cohesive zone by the dissection
of commercial blast furnaces some attempts have and are being made to
Pressure roloo Pt Pz = 1.25
14 67~~~~~~~~~~~~~ 14
12
~~+-++-H-tttt1
~~~~T-++~41+H10
~~~-rr++rHt1 08
0.6
04
02
600
550
Wu
500
Ir\ ....,
I~
V
~
\
450
0]
0.6
0.5
-- " IL
"-
........
%Si
0.4 "-
0.3
0.2
21-5-63 22-5-63
model, the heat required for the reduction of silicon and for the
overheating of the iron and slag, which was calledEe , was calculated on
the assumption that the silicon in pig iron was in an equilibrium state
with slag, although the use of this assumption might have some
restrictions. This concept is illustrated schematically in Fig. 3.1.16. One
of the comparisons is given in Fig. 3.1.17 between calculated and
observed relationships of Ee vs. %Si. The result obtained by CRM
showed one of the possibilities for profitable control.
In the Sakai works ofNSC,31 successful computer control of the blast
furnace was achieved on the basis of not only the thermal state in the
lower part of the furnace but also the permeability in the furnace for
stable and high performance operation.
dJ
I... -s Blast Moisture
wQ.-----
II -" Hot Metal
Coke 1000"(
_Burden_1000
C_'
0
Ec
SlAG VOlUME
- - Experimental curve
422 - - - Theoretical curve
635kgNTHM
::2 / =0075
I
f-
/ as~;
Z 315 SlAG VOlUME
~,
5;2
~/ /~/=O.IOO 658kg .NTHM
°SiO
211
V
~
~ IV
105
.-£-
-'
o
o 0.2 0.4 0.6
9b Si
Fig. 3.1.17. Comparison between theoretical and eXPoerimental curves for the
relationship of Ec and % Si. 0
Charged
Top gas materials
t t
Drying of the charge Shaft region
Indirect reduction
950·C
I
Indirect reduction Uppe r bosh
Solution-loss reaction regia
Water gas shift
reaction
1250·C
I
Tuyere I I
region Reduction of
Combustion of coke
Hot biast metalloids Hearth
-----
Decomposition of
Transfer of sulfur region
blast additives
from metal to slag
+
Cast materials
Fig. 3.1.19. Computed response curves of process variables to step changes in blast temperature, ore/coke ratio, and
injected oil. 32
GLOBAL FORMULATION 121
silicon content. Hatano et al. 34. 35 applied the model to the dynamic
control of real blast furnace operation thereby stabilizing the temperature
of hot metal.
Another dynamic model was proposed by Hatano et al. 36• 37 for
simulation and forecasting of behavior due to change in operating
conditions. This model is described in detail in Section 3.7.
Horio and Muchi38. 39 reported a mathematical model for analyzing
the dynamic characteristics of a blast furnace in the region between the
melting and tuyere levels, by using the conservation equations of heat
and mass together with heat exchange and chemical reactions. The
response curves were computed for the location of the melting zone and
temperature of molten materials at tuyere level to step changes in
operating conditions. It has been found that the movement of the
melting zone markedly affected the dynamic behavior because the time
constant for this process was as long as several hours.
J. 1.0 o 100 0
~
773 07S 025
" 0.8 1173 8SA 047
.2
U 0.072
is 0.6
e
g 0.4
Q
] 0.2
(3.2,18)
where
RH [kHW(l + l/KHw )(1 - isHW)213 r 1 (3.2.20)
Rw [kWF(l + l/KWF)(1 - isWF) 213 r 1 (3.2.21 )
DH [do/(2DsM)][(l - isHWr 1l3 - (1 - isWFr 1l3 ] (3.2.22)
Dw [do/(2DsF)][(l - isWFr l/3 - 1] (3.2.23)
F l/kn (3.2.24)
W2 = Rw(RM + DH + Dw + F) + (RH + DH)(Dw+ F) (3.2.25)
Spitzer et al. 52 proposed a three-interface unreacted core model for the
general analysis of the reduction kinetics of iron oxide, as shown in
Fig. 3.2.2. Hara et al. 53 modified the model thereby resulting in a series of
useful rate expressions for application to process analysis and this
method was used for analysis of a moving bed reactor4- 56 for hydrogen
reduction of iron oxide pellets. Murayama et al. 57 and Takahashi et at. 58
.-/
.------
/"
/
/
I
/
/
/
I ro
yeo
Fe
yeo.o
.
yeO,3
YeO,3
.
yeO.2
yeO.2
yeo. J
yeo. J
The overall reaction rate Rrper unit volume of the bed is defined as:
(3.2.38)
Assuming that the diffusion through gaseous film takes place steadily
and successively with the simultaneous processes of diffusion with the
pores and chemical reaction at the internal surface of lump coke, one
can derive the overall reaction rate given by eqn (3.2.41) from the rates
for both processes expressed by eqns (3.2.39) and (3.2.40).
Diffusion rate through gas film
= lTd;,Nccp~lkf2 . 273P'(Yeo - Yeo.o)/22-4Ts (3.2.39)
Diffusion rate in pore with chemical reaction
= EfmcNcCP;lk2 · 273P'Yeo.o/22·4Ts (3.2.40)
where irreversible first-order reaction is assumed:
R* _ lTd~cp~INc· 273P'Yeo/22·4Ts
(3.2.41 )
2 - (l/kf2) + (6/dcPc E rk 2)
(3.2.47)
where
k21 = exp(27·20l - 35 900/Ts) (l/atm· h) (3.2.48)
k22 exp(l4·240 - 18 350/Ts) (l/atm) (3.2.49)
k23 10·3 (l/atm) (3.2.50)
k25 = exp(29·588 - 36 760/Ts) (l/atm) (3.2.51)
Er = exp [(In 0·15)(Ts - 1073)/300] (3.2.52)
The equation for ~L is obtained on the basis of Curie's report68 and the
reaction rate constant k4 is obtained as follows:
k4 = 5-47 X 106exp ( -40 OOO/RTs ) (kmol(C0 2 )/m2 • h) (3.2.65)
In this relationship, the activation energy is estimated according to
the reports of Slonin69 and Hutting et al./o and the frequency factor is
obtained from the data observed by Britton et al. 71
The equilibrium constant K4 is represented as follows according to
data on the decomposition pressure by Perry et al.: 72
logK4 = -8202·5/Ts + 7·0099 (atm) (3.2.66)
Another expression of overall reaction rate for the decomposition of
limestone was presented by Miyasaka et al. 6O by considering heat
transfer and chemical reaction processes as the mixed rate control
steps:
R 4* --
(-ll.H4 )[J.- + ~ [(1 - Ji)-1I3 -
hgs 2keL
1]]
Rt = rrd~<p;;Wc' 273P'YH/22'4Ts
(3.2.75)
l/kf6 + 6/dcPcE ;k6
The transport coefficients included in this equation can be obtained
using the same procedure as that for the solution-loss reaction.
However, the diffusion coefficient required for the calculation of k f6 and
E;is that for water vapor in the CO-COz-Nz-HzO system instead ofCO z
in the CO-COz-N zsystem for the solution-loss reaction. The temperature
and pressure dependences of the diffusion coefficient of HzO are
expressed as:
(3.2.76)
The reaction rate constant k6 is derived by making a slight
modification of the equation presented by Kunugi et al. 78 according to
the reaction-interface model:
k6 = 4·83 X I04Ts exp( -17 31l/Ts) (m 3/kg . h) (3.2.77)
134 BLAST FURNACE PHENOMENA AND MODELLING
kmOl(H 2
(m 3 (bed)h
») (3.2.81)
Material balance on H 2 :
(3.2.92)
Vol
-..J
-
138 BLAST FURNACE PHENOMENA AND MODELLING
where the heat of fusion and heat of reaction are calculated as follows:
~mi(Lf)i = (3'7Fms,Fe + 3'6Fms,Si02 + 19'OFms,CaO + 26'OFmS ,Al20 3
+ 18'5Fms,Mgo + nOFms ,MnO) X 103 (3.2.97)
~Msj(-!:1HO)j = [5-45Fms,wus,i - 2·12Fms ,Fe203 - 7· 12Fms ,Fe304
- 31'13Fms ,wus,d - 42'6Fms ,CacOj + 29'2(0'21 + Xo)
X 60Fb/ll·2 - 28-4(60Fb)wsJI8 000
(3.2.98)
In the derivation of eqn (3.2.97), it is assumed that all the iron ore
charged melts as metallic iron after complete reduction, the CaC0 3
charged melts as CaO, and the other oxides melt in the same form as
charged, and that the total heat of fusion is calculated by adding the
heats of fusion for each component. For the derivation of eqn (3.2.98), it
is assumed that the heat of direct reduction comprises both indirect
reduction and the solution-loss reaction. Solution loss by water vapor is
included in solution loss by CO2 because of the small quantity of the
reaction, and the heat of indirect reduction by H2 is neglected because
the amount of reaction and the heat of reaction are both negligibly
small.
The heat of slag formation Qs and heat loss through the wall Qw
included in eqn (3.2.96) can be obtained from eqns (3.2.99)83 and
(3.2.100):84
The temperatures of gas and solid at the top of the bed are thereby
obtained by solving eqns (3.2.96) and (3.2.106) simultaneously for a
fixed operating condition.
/
~<o6~ ~
h~
oE
9 --.....--
g, 92 9" g4 go,
f V
e ~ e,
d i<e ~d,
-
d,
b
c ~ C?- CJ
0
~ ib,-b, - b 3r - - b4
0, 02 03 °4 O:J
Te t[ T~l Tb t, Tt
Temperoture T ['K]
(3.2.124)
(3.2.126)
TABLE 3.2.2
Specific Heat of Materia1s 85 cp = a + bT - cT- 2 + dT2 (cal/mol· 0c)
Tuyere
1
-+--+-J
Level
TgC-.d-C
>----------D>--------1.1
Fig. 3.2.4. Control volume at tuyere leve1. 20
where Ggr and Ggz designate radial and axial mass velocities of gas. For
simplicity, Ggz/G gr is assumed to be proportional to LJr and a is
introduced as an arbitrary constant:
(3.2.130)
Solving the eqns (3.2.128)-(3.2.130) with the assumption that T = TT
and Vgr = F 1/2lTL tR c are satisfied at r = Reo the following relationships
can be obtained:
Tg = Tc + f3 exp(8r 1- a ) (3.2.131 )
Vgr = Flra/nOOlTLtR~+a (3.2.132)
Vgz = (1 + a)F 1ra-1/nOOlTR c1+a (3.2.133)
where
f3 (TT - TJexp( -8~-a)
8 1]/(l-a)
1] 1·2lTL(l - Gl)hgslR~+a /<PccgldclPglFl
Assuming that the gas temperature is expressed by eqn (3.2.131) for
r = 0 to Rc and is given by TT for r = Rc to Dh/2, we can obtain the
GLOBAL FORMULATION 145
Rr VR:
In the derivation of eqn (3.2.134), a is assumed to be 1/2 since this value
has been found to give reasonable values of U z in the range 7-10 (m/s)
after many trials.
An overall heat balance between the top and tuyere levels in a blast
furnace, using the assumption that coke is at the same temperature as
molten materials at tuyere level, gives:
AoGsocsoTso = + cgOpgOFoTgO
A I GsI CsI Tc
- CgIPgIFITgml + Qw - Qs + I:.mi(Lr)i - I:.Msj (-IlHO)j
(3.2.135)
where
PgO = 1·2507 + O·726IYeo2.o - 1·l608YH2o.o - 0-447lYH2o.0
Fo = 47-4Fb /(l - Yeo. 0 - Ye02.0 - YH20.0 - YH2.0)
The procedures to calculate the values of I:.mi(Lr)i, I:.Mi( - IlHO)j' Qs
and Qw have already been given in Section 3.2.3. In order to eliminate
TgO, Tso , Tgml and F" eqns (3.2.96), (3.2.106), (3.2.114) and (3.2.134) are
therefore substituted into eqn (3.2.135), resulting in the following
expression for the coke temperature at tuyere level:
(3.2.136)
where
PI = n i - n4 X 10-\
nl = A(ml - 'l'N)I(l - 'l')N, n2 = B + A(M - moTso)/(l - 'l')N,
n4 = A(2c + d),
146 BLAST FURNACE PHENOMENA AND MODELLING
L (l - aj)(~HDRj·
8
qj
j =j
q2 (l·2507~+ O·726I-r)R; + O·5246R; + 1·9768R: + O·7143R~
+ O·5364R~ + 2·5014R;
q3 = 6(1 - t:)hg.(Tg - Ts)/<Pdp
(3.2.138)
GLOBAL FORMULATION 147
P'F,O, Fo,
egO, G gO , TgO
Stock Line
Cso,Gso, tm
L,
dZ
L,b
H
Tgz+dz
GszI·dz Ggz+dz
Db
Pgj, FJ
Tuyere Level
where
L a;(-~Ht)Rj'
8
q4 =
The heat transfer coefficient between gas and particle streams, hg5' the
mean diameter of particle, dp , and the overall heat transfer coefficient
through the wall are all important parameters in the above differential
equation system, These parameters are determined by using the
following relationships.
The heat transfer coefficient, h g" is estimated by Ranz's equation: 86
Nu = 2,0 + 0·6(Rep y!2(Pry/3 (3.2.150)
GLOBAL FORMULATION 149
where
Nu = hgsdp/kg, Rep = d p Gg/f.1g, Pr = cgf.1g/kg
The mean diameter of solid particles, dp , is evaluated from the
harmonic mean diameter:
(3.2.151 )
The overall heat transfer coefficient through the wall can be obtained
as follows:
u (3.2.152)
where
TTDb(Ljsin WI + Lb/sin W 2 + La)
- TT[L;/(sin WI • tan WI) + LV(sin W2 . tan (2)] (3.2.153)
Since blast furnace gas is considered to be a gas mixture of CO, COb
H 2, H 20 and N 2, the average heat content may be expressed as follows,
by component addition:
cg = LI(Cp)iY;!LIMYi (3.2.154)
The average heat content of the solid stream is also defined in the
same way:
(3.2.155)
where the specific heat for each component has been given in previous
literature. 20, 81
The longitudinal distribution of process variables can thus be
estimated from the above kinetic model together with boundary
conditions which have been determined previously in Sections 3.2.2 to
3.2.6.
To illustrate the procedure for estimating the situation in a blast
furnace, a schematic profile of the furnace is shown in Fig. 3.2.6. It is
assumed that the rate of dust elutriation from the furnace throat and its
composition (4) remain unchanged, and that the ratios of steam injection
and of oxygen enrichment per unit volume-flow rate of blast are held
constant.
Suitable values for the temperatures of hot metal and of slag (5) and
for the concentrations of C, Mn and Si in hot metal (6) are selected on
the basis of the results of practical operations. The operating variables
Vl
o
-
Volume rate of flow and temperature of blast, oil ratio, 1:1:1
CD
steam ratio and enrichment of oxygen in blost
contained in the model are top pressure (2), blast volume, temperature
of blast, oil ratio, steam ratio, oxygen enrichment (1), compositions of
solid particles fed into the furnace, and the diameter and fractional
pre reduction of iron ore (3). Boundary conditions at the top level of
burden bed (8, 11) and those at tuyere level (12, 13) can be determined as
shown in the previous section, and the values of mass-flow rates of iron
ore, coke and limestone in the charge materials (8) (We, We> Wj) are
given arbitrarily.
Under the boundary conditions at the top level of burden bed (2, 3, 8,
9, 10, 11), ten ordinary differential equations, (3.2.137)-(3.2.146), and
three algebraic equations, (3.2.147)-(3.2.149), are solved simultaneously
on a digital computer. The Runge-Kutta-Gill method is employed in
obtaining the numerical solutions for the model. In this way, the
longitudinal distribution in process variables (14) can be determined.
If the values of Tg , T" Fg , Yeo and YH2 at tuyere level thus obtained in
(14) agree with those obtained in (12) and (13) within the limit of
allowable errors, and the conditions offs = 1,j; = 1, andYeo2 = YH20 = 0
are satisfied, then the given values of WQ) We and WI in (8) and the
longitudinal distributions of process variables obtained as (14) can be
considered to be valid. But, if satisfactory agreement between them is
not obtained, then the preceding values of We, We and Wj are modified
and the same computation is carried out repeatedly until good
agreement is found.
I:C
Po kg/m 2
2.033)( 10' §
---- 5033x1O'
.§
trl
i
"tI
:I:
1400
,
~
~
t:l
0.2 f" f, I 0j4 0.6 O.S I 0 I V, 1m secl
~
t:l
I ! P/l04(kg'm~) I
trl
oI 02 yco, Yco, [_I 0.3 04
2~3 21,4 2.15 2'.6 2 '7 ~
FI( / 10 5lNm 3 /minJ o
Fig. 3.2.7. Longitudinal distribution of process variables in blast furnace (A) for the case of high-pressure operation
(do = 19·35 mm, F b = 2942·2 N m 3/m in, T
b = 1366° v w = 23·2 g/Nm3,x0 2
"'''''st = 0)· 19
GLOBAL FORMULATION 153
figure, top pressure is the only parameter changed and predictions for
the two pressures under consideration are shown as either solid or
dashed lines.
From Fig. 3.2.7 it is clear that the variations in the distributions of
temperatures for gas and solids are not large, although the distributions
shown by the dashed lines in the shaft and belly are lower than those
shown by solid lines. That is, an increase in the feed rate of solid
particles caused by an elevation in gas pressure in the furnace brings
about a decrease in the temperatures of the gas and the solid
particles.
As the top pressure becomes higher, the molar fraction ofC02 ,Yeo2,
increases and that of CO,Yeo, decreases. It is especially noteworthy that
in the case of the dashed line, i.e. high top pressure Y C02 shows a larger
value than that of Yeo at the furnace top.
The fractional reduction of iron ore in the case of higher pressure is
lower than in that of lower pressure, but the former proceeds more
rapidly as the solids approach tuyere level. Furthermore, the elevation
of top pressure leads to lower linear velocity of gas and to less pressure
drop.
Variations in the production rate of pig iron, Wp , and the carbon
ratio, Cn accompanying the change in top pressure are illustrated in
Fig. 3.2.8. This figure shows that the increase in Wp and the decrease in
Cr caused by the elevation of top pressure are comparatively large in the
range of top pressure below about 4 atm within the range 3000-
3500 Nm3/min in blast volume.
Generally, the driving force for indirect reduction of iron ore
increases with increase in top pressure, and this increase in reduction
rate of ore leads to better productivity. However, if the top pressure
exceeds about 4 atm, then the value of CO/C02 comes to thermodynamic
equilibrium with the reduction of iron oxide, so that improvements in
productivity cannot be expected from elevating the top pressure more
than about 4 atm.
200
,
\
470
-- ---
\ Wp
190
I
\
\
\ /
,- ""
--
,..
460
180
\ ,/
Fb Nm 3/min
450 ~
~ .z
-'= \ 2942.2 Q
~ \
0. 170 \ 3500 440 =
Ol
S \
\
U
160
"" 430
150 420
140 410
1 2 3 4 5 6
Po X 10- 4 Ikg/m')
Fig. 3.2.8. Effect of the top gas pressure, Po, on the production rate of pig iron,
Wand carbon ratio, e p in blast furnace (A) (do = 19·35 mm, Tb = 1366°K,
P'
W st = 23·2 g/Nm ,x~ = .
3 0) 19
200 480
- - Po = 2033 xl 0' kg/m'
--- Po=4.033x 10'
180 460
OJ
~ E-
?
160 440 g
~
U
/
,/
140 420
-- --
/"
/"
...- /"
120 400
10 15 20 25 30
do Imml
Fig. 3.2.9. Effect of the diameter of iron ore, do, on the values of Wp and Cr in
blast furnace (A) (Fb = 2942·2 Nm 3/min.j Tb = 1366°K, wst = 23·2 glNm 3,
x0 2 = 0).1
300 500
-'=
? 200
?;~
100 ~-----L------L-----~----~400
2000 3000 4000 5000 6000
Fb IN m3/ minl
Fig. 3.2.10. Effect of the blast volume, F b , on the values of Wp and C r in blast
furnace (A) (do = 19·35 mm, Tb = 1366°K, wst = 23·2 g/Nm 3, x0 2 = 0).19
156 BLAST FURNACE PHENOMENA AND MODELLING
(J)
155 C, 450 E-
.<: ~,
g
£
:;
; 150 425
0
145 400
1366 1416 1466
Tb lOKI
Fig. 3.2.11. Effect of the blast temperature, T b , on the values of Jfj, and C r in
blastfumace(A)(Po = 1·433 X l(f kg/m2,do = 19·35 mm,Fb = 2942·2 Nm3/min,
w st = 23·2 g/Nm 3, XC>:! = 0).19
GLOBAL FORMULATION 157
2C + O2 = 2CO
dB -52·85 kcal/mol(02) (3.2.156)
X 0,
\
\ 007
\
\
I:tI
\
\
\ ~
>-3
] vI \\ \ f, ~
I, "
121- --\-_':;-!{ . . . . .
..... ~
"
~
t'rl
"tI
16 ::r:
B F IAI ~
20
o
~
IUUU ,
500 Tg L, [OKI
~
90U 10uU 1100 fJ b [kg m 3 (bed)) 1200 1300 ~
tJ
05 I" I, I " 1.0 P /10 4 [kg m 2 )
o1 02 03 Y CO I I 04 05 ~
2Y 3U 3.1 32 3.3
P
F~ / 10 51Nm 3 hrl
Fig. 3.2.12. Longitudinal distributions of process variables in blast furnace (A) for the case of oxygen-enriched operation
(Po = 1'433 X 104 kg/m2, do = 19·35 mm, Fb = 2942'2 Nm3/min, Tb = 1366°K, W st = 23'2 glNm3, x0 2 = 0'07).19
GLOBAL FORMULATION 159
200r-------------,
190
, 500
g
;'
U
450
2 3 4 5 6 7 8 9 10
xOz 1%1
Fig. 3.2.13. Variations of the values of Wp and C r caused by the change in the
ratio of oxygen enrichment, xo)~ in blast furnace (A) (Po = 1·433 X 104 kgfm 2,
do = 19·35 mm, Fb = 2942·2 Nm3/min, Tb = 1366°K, Wst = 23·2 g/Nm3).19
N
~
tTl
'1:l
:r:
tTl
BJ.[A[ Z
o
~
~
Tg, T,I"K[ 400 [600 800 1O~0 1200 1400 1600 1800 2000
>
Yeo, Yeo,[' 0.1 0.2 0.3 04 ~
I ! ! ! tl
02 f" f,'. f, [. [0.6 0.8 1.0 P T 10 '[kg, m 2[ ~
I I I ! ,
r
.; p t:'
o t Fine el 01 III
.;: 40
20
0.2 04 06 0_8
Fig. 3.2.15. Rate of increase in the production of pig iron, ~p, and that in the
coke saving, (c, caused by the pre-reduction of iron ore (standard operating
conditions). 19
162 BLAST FURNACE PHENOMENA AND MODELLING
range ofIso above 0·3. Data observed by Woolf,92 Peart et al. 93 and Fine
et al. 94 in experimental or commercial blast furnaces are also plotted in
the figure. Comparing these observed data with the calculated curves
obtained by the experimental work, the theoretical result is slightly
larger than the experimental data in both';p and Sc. It seems that these
deviations are caused by the differences in operating conditions and in
the profiles of the blast furnace. However, the curves determined in the
work show similar variational trends with the data observed by other
investigators.
problem, the effect of flow rate and temperature of the injected gas and
the injection level were examined through the mathematical model,
thereby clarifying their effect on the production rate and fuel ratio. A
similar analysis was also carried out by Kobayashi et al. 97 on the
injection of reducing gas produced by nuclear energy into a blast
furnace.
An estimation on the lowest fuel ratio of the blast furnace was
attempted under specified operation conditions by Togino et al. 98 by
means of the mathematical model. 396· 5 kg( coke )/t(pig) was reported as
the lowest limit for the operation of the blast furnace under the specified
conditions.
A slight modification of the model was made by Miyasaka et al. 99
whereby an effective cross-sectional area for gas flow was introduced in
the lower part of the furnace. As shown in Fig. 3.2.16, this modification
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 Yco' yco" f, f, f I I-I
0.020.04 1""Y",01-11.0 1.5 2.0 2.5 Pllotml
I I I i
2004006008001000120014001600180020002200 Tg , T, I'KI
'0 Tg
Q
o
r-
meant that the gas was assumed not to flow through the dead zone, and
that the molten materials formed in the melting zone, dropped only into
the dead zone. The computed distributions of pressure and temperature
under these conditions were reported to agree well with those measured
in an actual blast furnace as shown in Fig. 3.2.17. Abnormal increase in
blast pressure sometimes occurs in actual operations and this may
cause a serious decline in the state of the operation. As a result of
analyzing this abnormal situation, the increase in blast pressure was
found to be predicted by the mathematical model about 3 hours in
advance of the actual problem.
The dissection of commercial blast furnaces, of which recent
advancements are summarized in Chapter 1, has shown significant
nonuniformity of conditions in the radial direction. An attempt was
Wal l Cenler Wa ll
3 Iml
Belly
Bosh
Tuyere
Tuyere
H,rohala I BF
I~ Compuled cohesive zone. Cohesive zone o blained by d,sseclionl
made by Ono et al. 100 to analyze this nonuniformity. In the analysis, the
blast furnace was divided into 20 annular elements in the radial
direction. The one-dimensional mathematical model was applied to
each annular element and numerical computation was conducted
according to the boundary conditions specified at the top from
measurements taken during actual operation. This computation gave
the radial distributions of temperature and fractional reduction as in
Figs 3.2.18 and 3.2.19. It is possible to obtain the upper shape of the
cohesive zone based on the isotherms as shown in the figures, and the
very good agreement between the calculated and observed shapes ofthe
cohesive zone shown means that the mathematical model can predict
the approximate shape and position of the cohesive zone for stationary
operation of the blast furnace.
Cenler Wall
20
averaged particle size dp and the voidage &", the Ergun equation
expressing the pressure drop of gas may be rewritten as follows:
aPiaz = (Pg/gc)[l - n01 . '1'(0 . u g (0 2/ [(j)(0 . d p (0 . &"(01 (3.3.1)
where the drag coefficient '1'(0 is defined by:
'1'(0 == 150[1 - n;)]lRep(0 + 1·75 (3.3.2)
Rep(0 == (j)(0· d p(0 . &"(0· ug(;)/v
Because the value of Rep is very large in a blast furnace, the radial
change in '1'(;) is slight even if there existed radial changes in d pj and Gj
in each layer. Consequently, it may be assumed as '1'(0 = const. == '1'.
Moreover, itis assumed that the shapefactor(j)(0 = ¢I = ¢2 == ¢ = 0·64.
Let each volume of ore and coke burdens in a block enclosed between
the radial position ; and (; + d;) be designated by VI; and V2;,
respectively. Then, n0 can be readily expressed as:
&(0 = (GI VI; + G2 V2;)/(VI; + V2;) = A + B; (3.3.3)
where the dimensionless factors, A and B, are related to the charging
conditions through the following expressions:
A 8 1VI + G2 V2 + (2/3)7TR~A(81 - 8 2)
B == -7TR~A(81 - 82)/(VI + V2), A == tan a2 - tan a I (3.3.4)
168 BLAST FURNACE PHENOMENA AND MODELLING
~i = ~l.i + ~2.i
~I.i == [VI + lTRjA(2/3 - O]/lTRr
~2.i == [V2 - lTRjA(2/3 - O]llTR~
C i == [V,/D pl + V2 /Dp2 - (2/3)lTRjf A]/lTRl
Di == fARi!Rr
f == l/DP2 - l/Dp,
Dpj == dpj ' c/(l - Cj) (j = 1,2) (3.3.6)
U --_.
Fg A +B~ (3.3.10)
N - 2lTR;Ei ICi + Di~
where Ei is a dimensionless factor defined as:
GLOBAL FORMULATION 169
S.L ~--t----\
B.F.ID III
Do Iml 7.50
D.11ml 11.20
Db Iml 10.30.
Z, Iml 17.30
Z, Iml 2.80
Z, Iml 0.61
and the bulk density of its layer can be represented by eqns (3.3.19) and
(3.3.21), respectively.
dTsddt = K,(Tgl.i - T s') + He(-AHe)
+ Hcl44(cp)co2 - 56(cp)co + l2csdTs' (3.3.19)
where K, and He are defined as follows:
K, == a,hgs1.Jpbdcs' + Ts,(dcs,/dTs' )]
He == Ce.o(dfcldt)/Pb, [cs! + Ts,(dcs,/dTs' )] (3.3.20)
Pb' = Pb'.O - l2Ce.ofe (3.3.21)
where the first and the second terms of the integrals in the left-hand side
of eqn (3.3.22) represent the heat amounts transferred by the heat
exchange between gas and solid particles and by the heat-in-mass
transfer, respectively. Each integral term on the right-hand side shows
the change in the heat content of the gas and the heat transferred in the
radial direction, respectively.
To estimate the value of (, an effective thermal conductivity102 has
been applied for analyzing the observed temperature distribution in a
cylindrical bed. 103 As a result, the following simple correlation has been
obtained:
(3.3.23)
172 BLAST FURNACE PHENOMENA AND MODELLING
In eqns (3.3.27) and (3.3.28), the variables Ts1,je,Pbl and Csl' with suffix
i, are defined as those respective values at t = t f •
It is to be noted in eqns (3.3.25) and (3.3.27) that the gas temperature in
the layered burdens case is governed by three thermal flow ratios (y, L,
M) instead of y alone for a homogeneously mixed burden.
3.3.2.4. Pressure drop of gas flowing through ore and coke layers
The pressure drop of gas passing through each layer of burden with
thickness ~j. i, and ~Pj. i, can be evaluated on the basis of the Ergun
formula described by eqn (3.3.1). Then the gas pressure at the lowest end
of each layer is given as follows:
PI.i = P 2. i + M 2. i (3.3.40)
P2. i + 1 = Pl.i + Ml.i (3.3.41)
TABLE 3.3.1
Data for numerical analysis of blast furnace (DII)
W1 (kg/ch) 38950
WI (kg/ch) 11900
V1 (m3(bed)/ch) 21'68
VI (m\bed)/ch) 17-25
d po (m) 0'0196
d pl (m) 0'0152
d pc (m) 0'0519
Fs (m3(bed)/ch) 272-5
e (h) 0·1429
Co. 0 (katm(O)/m3(bed» 26'86
Cl. O (kmol(CaCONm 3(bed» 0·1387
Cc. o (katom(C)/m3(bed» 49-44
T s1. O CC) 30a
TsI.o (0C) 30a
T g2.1 CC) 203
P2.1 (kg/m2) 14300
Yeo. 0 (-) 0'241
Ye02.0 (-) 0'190
YH20.0 (-) 0'013
YH2.0 (-) 0'036
YN2.0 (-) 0'520
Fg (Nm 3/h) 311600
U (kcal/m 2 • h· 0C) 15
aEstimated value.
176 BLAST FURNACE PHENOMENA AND MODELLING
and z
WRITE
Results of i,z,T s ,T g ,fk,Pb'YCO'YC0 2 ,F g,u,
and p ____------------------~----
YES
YES
Fig. 3.3.3. Flow chart for computing the longitudinal distributions of process
variables.
GLOBAL FORMULATION 177
TABLE 3.3.2
Numerical Data for Computation Based on Two-dimensional Model
cations to the pattern of Ao(O are repeated until the final pattern is
obtained, neglecting the radial change in YH2.0 and YH20.0:
where
ME
0.4 r--~~::::::::""",----_l2.0 ;;
z
::0
Fig. 3.3.4. Radial distributions ofe, d p and UN at the top of blast furnace (DII).
178 BLAST FURNACE PHENOMENA AND MODELLING
Figure 3.3.5 shows the radial profiles of the temperature and the
compositions of CO and CO2 of the top gas in B.F.(DII), determined by
the procedures mentioned above.
500 r - - - - - - - - - - - . , 0.4
400 0.3
.'00 0.1
I 00 '---_--'-_--L-_--'-_--"'------' 0
o 0.2 0.4 0.6 0.8 10
, I-I
Fig. 3.3.5. Radial distributions of Yeo, Yeo, and Tgl. I at the top of blast
furnace (DII).
0 02 0 .4 ) 10 0 1m seel 12
I", I,. f, I t: j,!
1 I I I I
05 1.0 20 2.5 3.0
I 1 I I I
2.8 29 3.1 3.2 3.3
10
0 51
10
12
]
N 14
16
18
et al. 104 observed the inner features of Hirohata No. 1 blast furnace
quenched by water. A number of annular layers, in which the iron ores
had been softened and partly molten, were detected over the zone from
the tuyere to the middle level of the shaft. These softening layers would
be located in the range surrounded by the isotherms of 1200°C and
1400°C in Fig. 3.3.8. The pattern of the cohesive zone illustrated in
Fig. 3.3.8 is similar to the findingsl04 in the dissected furnace and it
should be noted that the inversely V-shaped cohesive zone has resulted
from the operation with a strongly centralized gas flow both in this
calculation and in Hirohata No.1 furnace.
10
12
E
N 14
16·
18
20
22
24
26 B.F. ID III fo
2B
-
(mass flow) (reaction)
N n
- -
(j = g, s, 1), Dg = 1, Ds = Dt = -1 (3.3.43)
-
and Kjn is the effective thermal conductivity. As for fluid flow in porous
media, this dispersion of heat stems from hydrodynamic fluctuations of
G j. Parameter 1Jj is the fractional acquisition of heat of reaction
including the extent of heat-in-mass transfer.
--
below seems to apply successfully to the nonuniform flow of gas in the
blast furnace: 23. 28. 106-113
gradP = -(j; +hIGgl)Gg (3.3.46)
where
150(1 - f:)2f.lg/gcpg(tjJd p )2f:3
1·75(1 - f:)/gcPg(tjJd p )f:3 (3.3.47)
On the other hand, we have less understanding of the equation of
motion of burden materials in the furnace. A simple and probable
principle which simulates the burden flow is given by potential flow
theorf? which prescribes the irrotational movement of fluid particles
- -
and is expressed as:
ill = rot V sj = 0 (j = 0, c) (3.3.48)
This equation may be utilized whether the burden is in the form of a
solid or a liquid.
184 BLAST FURNACE PHENOMENA AND MODELLING
L f3k R:
N
o (rGjr)/or + o(rGjz)/oz - Dj = 0,
k~1
(j = g, s, 1), Dg = 1, D5 = DI = -1 (3.3.49)
which can be satisfied by working in terms of the stream function ljIj
defined as:
Sg == f( ik~1
f3k R : ) r dr (3.3.50)
oP/or
oP/oz
--
-(j; + 12lG g l)Ggr
-Cil + 121 Ggl)Ggz
(3.3.51 )
(021f1
+h:1" _! Olfl 021f1 OSg)][(OIfl
:1 +:12+:1
S)2 (OIfl)2]
:1 + g + ur
:1
ur r ur uZ uZ uZ
(3.3.53)
-
(3.3.54)
ur r ur uZ- ur uZ L....
k =1
where W == 11 + 121G g l.
The iterative solution of eqn (3.3.54) also gives the pressure at all
points in the furnace. We usually need to know the pressure and the
temperature during the course of the solution for IfI because their
variations may affect gas density which in turn requires recasting of the
flow resistance.
+ (s g
olnpj _ OSg)
oz oz = 0 (j = o,c) (3.3.56)
which gives the stream function for ore or coke flow in the domain of
interest. Domain borders on which boundary conditions should be
stipulated may comprise not only the furnace geometry but also the
contours of the stagnant coke cone and the raceway for coke flow, and
the so-called 'dry zone' in front of the tuyeres for ore flow. The velocity
field of each material can be determined also by inserting the converged
value of the stream function into eqn (3.3.50). Superimposition of the
two velocity fields obtained approximately accounts for the global flow
field of burden.
3.3.6.3. Temperature
The expression of eqn (3.3.44) in angular symmetry may be derived to
yield:
(02Tj 1 OTj) o2Tj oKfr oTj oKfz oTj
+ Tr a; + ----a;- a;
e e
K jr or + -;:a;: + K jz OZ2
L R:(-!:l.Hd = 0
N
- f>jhgba(Tg - T b) + 1/j
k =1
(j = g, b), 1 (3.3.57)
where Tjz designates the axial linear velocity of fluid. The observed
relationship I 14 between Pejn and particle Reynolds number,
Repj( = d p Tjp/J1j)' normally gives the following constant over the Repj
range possible in the blast furnace:
Peg, = 10, Pe gz = 2; Pel, = 50, Pelz = 0·5 (3.3.59)
(b) Effective thermal conductivity of burden (KD. This may be
approximated to the effective thermal conductivity of solids (K~)
because of a small hold-up in the dropping zone. Since the solid-solid
thermal conduction through the point of contact is relatively slight, K~ is
governed by the indirect and direct radiation whose mechanism was
formulated by Shotte l15 as follows:
K~ (l - 8)/(l/ks + l/k,) + 8k"
k, = 1·97 X 10- 7 dp(Ts + 273)3 (kcallm· h· 0c) (3.3.60)
(c) Interphase heat transfer coefficient (h gb). When we define hgb based on
eqn (3.3.44), we may tacitly assume Tb as representing the mean
temperature of solid particles with and without the surrounding melt.
Thus hgb should be an overall parameter involving the true gas/burden
film heat transfer coefficient (h~b) and the burden conductivity (kb). The
expression for spheres was given by Stuke l16 in the form:
l/hgb = l/h~b + (dp /lO)k b
(3.3.61)
where Bi = h~bdp/kb is the Biot number. Thermal conductivities of solids
take the values of 0·5 for coke and 1·4 for ore materials, in
kcal· m· h· °e ll7 The true heat transfer coefficient, h~b' is well
correlated by Shirai l18 according to:
8(h~bdp/kg) = 2·0 + 0·75 P r l/3 Re~!2 (3.3.62)
where 8 is the void fraction of the packed bed and Pr (= cg J1g1k g ) refers to
the Prandtl number.
(d) Specific heat ofgaslburden (Cj). The specific heat of multicomponent
gas/ore-burden can be evaluated by:
n n
(j = g,b) (3.3.63)
i =I i =I
where Ci is the specific heat of each component i, and it is expressed as a
temperature function.
188 BLAST FURNACE PHENOMENA AND MODELLING
Input data:
1) Furnace geometries
2) Operating conditions
3) Burden distribution
4) Physical and thermal properties
of cohesive zone
NO
Fig. 3.3.10. Flow chart for seeking the shape of the cohesive zone.
190 BLAST FURNACE PHENOMENA AND MODELLING
zone which may range between the isotherms of 1200°C and 1400°C
would strongly affect the gas flow patterns and temperature distribution
in the course of the iterative step. Thus a convergence criterion should
be specified with respect to the shape of the cohesive zone. The
computational grid in this calculation contained 30 X 120 points.
,-..
()
I I
I (l)
I
(/)
a
4.0 ,-..
2 '"0
I (l)
I
I
I
t9
I
I ""a
3.0
I
I
a "-tD
2
I
I
I
C
I
I
I III
CJ
a
+--~--f-O
1.0
0.0
1.0 0.5 0.0 0.5 1.0
~=rJRb(-)
It is of interest to note from Figs 3.3.12 and 3.3.13 that the distorted
dome associated with the inner shape of the cohesive zone corresponds
to the developed outflow of gas through the coke slits in that region. This
fact underlines the important role of the slit gas flow in the construction
of the inner shape of the cohesive zone.
Figures 3.3.14 and 3.3.15 show the computed results for the case where
al = a2 = 25°. In this case, the gas flow path which minimizes the total
pressure loss between the tuyere and the top is towards the peripheral
~ (-)
4
,....,
()
Q)
OJ
.......
....;::J ,....,
4 '"0
0..0 Q)
Ie:: 8
e; e...
s
"- 0.4 "-t.:J
0: CJ
1e:: 0 •3 2 110
~- C)
0
0.2
0.1
+-----+0
0.0
0.0
1.0 0.5 0.0 0.5 1.0
~ (-J
wall because the global flow resistance of the lumpy zone distributes
uniformly in the radial direction. Consequently, hot blast inject from
the side wall flows towards the peripheral region of the furnace and ore
burden at that location is increasingly fused until a steady state is
attained.
Thus, an even distribution of ore/coke ratio, in contrast to the former
case, cannot suppress a preferential fusion at the peripheral part. As a
result, a V-shaped cohesive zone appears, as in Fig. 3.3.15. This must be
g (-)
P 600
0)
r
..
C)
r
tIC
"'''!I1od~----'-0
~O)
BOO
1000
+-----+0
1200
1800
0.0
1.0 0.5 0.0 0.5 t.O
~ (-)
Fig. 3.3.13. Calculated isotherms of gas and burden together with radial
distribution of burden temperature (aj = 25°, a2 = 28°).
194 BLAST FURNACE PHENOMENA AND MODELLING
~ (-)
I I
2 U
(I)
I
,
I (/)
,--., 0.7 a
+-'
,--.,
0...0" 0.6 4 "0
(I)
Ie .D
2 '-'
e=- 0.5
, C'J
El
"-txl
I
"- 0.4 ,a
I
4
5: C
Ie 0.3 2
e=- 0
QD
0.2 a
'OF==--- - - +, O
0.0 ,,
I
I
I
I
0.0
\.0 0.5 0.0 0.5 \.0
~ (-)
~ (-)
,...., ~
$-J
OJ
r- 0
X In
0 r-
2
K:~~----I-O
1800
0 .0
1.0 0.5 0.0 0.5 1.0
~ (-)
Fig. 3.3.15. Calculated isotherms of gas and burden together with radial
distribution of burden temperature (al = 25°, a2 = 25°).
~/EjCJ + C div Vj - D e V
j 2C j = Rj(CI>"" Cn ) (3.4.2)
where subscript i denotes the chemical species and subscript j denotes
the phase, i.e. gas, liquid, or solid. Assuming steady state conditions:
D
-Dt =
D
-(Ep·)
Dt J J
. -V =
+ p.J dlV J
LR.M·1 1
(3.4.4)
where the diffusion term in eqn (3.4.2) was neglected for the reason
described later.
By assuming steady state conditions, eqn (3.4.4) becomes:
(3.4.5)
The gas velocity in the axial and radial directions is obtained by using
the above equation and the stream function IjI which is defined as
follows: 125
(3.4.6)
Vgz IjI,J(pgr)
Furthermore, by using the equation of state for gas given by p = pgkTg
and (P2)", = (P2),w an elliptic partial differential equation of the second
order is obtained. This equation is solved numerically using finite
differences. The numerical solution of IjI thus obtained gives the
distribution of gas velocity in the furnace by using eqn (3.4.6), and the
pressure distribution by using eqn (3.4.1).
a xy and f3XY in eqn (3.4.1) are the tensors which characterize the
anisotropic permeability introduced for considering cross-flow, namely
the gas flow in the radial direction in the furnace. This cross-flow has
been found in the analysis of the cohesive zone in quenched blast
furnaces.
The tensors are determined as follows. The charged materials in the
blast furnace may be divided into ore and coke layers; by assuming
isotropic permeability in each zone, the following equations may be
obtained.
In the ore layer
where
gradP - -
-(aopg I Vg 1+ f3o) V g (3.4.7)
f30
198 BLAST FURNACE PHENOMENA AND MODELLING
(3.4.8)
where
By the use of am Po, a e and Pc, the permeability vertical to the layer
(aJ..,p-L) and the permeability parallel to the layer (all,PII) are
approximately obtained as follows by assuming vertical flow to the layer
(VJJ or parallel flow to the layer (V;I)'
(aJ Permeability vertical to the layer. The pressure drop in the vertical
direction at the ore layer or the coke layer can be presented as
follows:
(P,i..)o = -(aOpgVJ. + Po) Vi.. (3.4.9)
(P, -t.)e = -(aePg Vi.. + PC> Vi..
Therefore, by assuming that the thicknesses of the ore layer and coke
layer are AXo and AXe, respectively, the total pressure drop vertical to
the layer at both layers is given by the following equation:
(3.4.10)
where
AX=AX+M
o. e (3.4.11 )
By substituting eqn (3.4.9) into eqn (3.4.10), the following equation is
obtained:
AX (ai..pgVi +Pi..Vd = AXo(aopgVi +PoVJJ+Me(aePgVi +PeV-t.)
Comparison of the coefficients of Vi.. and vi leads to the following
equations respectively:
Mai.. = Moao + Meae
MPi.. = MaPa + MePe
Thus the permeabilities vertical to the layers are represented as
follows:
a..L = (Moa o + Meae}!AX (3.4.12)
P..L = (MaPa + MePe)!M
GLOBAL FORMULATION 199
(b) Permeability parallel to the layer. Similarly the pressure drop in the
parallel direction at the ore layer and the coke layer may be given as
follows:
(P,")o = - [a opiVII)o + fio](V;I)o (3.4.13)
(P,II)c = -[acpg(V;I)c + fic](V;I)c
(3.4.16)
-
The diffusion term was neglected in the mass conservation law shown
by eqn (3.4.2) because of the following reason. The convection term
D(EjCJ/Dt = Vj . grad C has a value of about 3 X 10- 3 kmol/(m3 • s)
because the gas velocity in the actual furnace is about 1 mls and grad Ci
GLOBAL FORMULATION 201
D (Epli)
Dt + ~iPj div --
Vj = RiM, (3.4.18)
202 BLAST FURNACE PHENOMENA AND MODELLING
-
conductivity k e of gas at 1000°C is 1·9 X 10- 5 kcallm 2 • s . °C and the
-
average value of V 2Tg is about 200°C/m2. On the other hand, heat
transfer by the gas flow CgpgV g . gradTg becomes about 12 kcall(m 3 • s)
because V g is about 1 mis, CgP g is about 0·0755 kcallm 3 and the average
gradTg at the top of the furnace is about 160°C/m. Therefore heat
transfer by conduction is much smaller than heat transfer by gas flow,
by a factor of 103, and for this reason, in this model, the following heat
transfer equation is adopted as a first-order approximation:
(3.4.21)
0.21-----"""'\
y
0.1
o~--------~--------~--~
o 1000 2000
Solid temperature lOCI
(b) Heat transfer coefficient between solid and liquid Heat exchange
between the dripping liquid and the solid surface can be basically
divided into two portions: heat transfer in the liquid and conduction in
the solid.
The heat transfer coefficient for the solid is obtained by averaging the
integrated results of unsteady state heat conduction in the solid when
the liquid is in contact with the surface of the solid:
hs = 2 (ksCcPs Vi) 1/2 (3.4.24)
TTds l
The heat transfer coefficient for the liquid is obtained by modifying
the forced convection heat transfer equation: 128
hI = 0·664 kl l/3 l
d PrI Re I !2 (3.4.25)
or
-RiMi + ~i~RiMi
1
(3.4.30)
(3.4.31)
or
d -~hdT
k J J
- Tk)/f> + Q.J - c.r.~R·M
J J ill
dz (CjIj) = E (3.4.32)
jPj%
Here the denominators in eqns (3.4.29)-(3.4.32) represent the mass'flow
rates.
206 BLAST FURNACE PHENOMENA AND MODELLING
By using this equation, good convergence was obtained even when the
larger mesh distance was employed.
Start
End
Fig. 3.4.3. Flow chart of calculation; T is the temperature of gas, solid, and
liquid; IjI is the stream function of gas.
208 BLAST FURNACE PHENOMENA AND MODELLING
TABLE 3.4.1
Blast Furnace Profile and Operating Conditions
o/c:t:]
T
I
t
0.1 m/min
T
I kg/sec. m2
800~TOP
gas
'c
o
1400·C
1200
1500
1800
2100
Fig. 3.4.7. Temperature distribution of gas (- - -) and solid (--) in the blast
furnace; (_. -) boundary line between moving and stagnant zones.
212 BLAST FURNACE PHENOMENA AND MODELLING
1400·C
1500
1600
Fig. 3.4.9. Mass fraction of Fe203 and Fe in the blast furnace; (_._)
boundary line between moving and stagnant zones.
\
I '
\ o
Fig. 3.4.10. Mass fraction of FeO in the blast furnace; (_. -) boundary line
between moving and stationary zones.
co/co,
4tj° pg
as
"- ,,
\
\
\
\ \
\
\
\
\
\
o
Fig. 3.4.11. Mole fractions of CO (--) and CO 2 (- - -) gas in the blast furnace;
average CO/C02 of top gas = 1·02.
--
form is used as the fundamental equation for computing the pressure
distribution in a blast furnace:
-
Equation (3.5.1) is a nonlinear equation with respect to the velocity
vector G g. It is therefore linearized as eqn (3.5.3) for convenience of
216 BLAST FURNACE PHENOMENA AND MODELLING
G is assumed to be
--
numerical analysis. This means that the change in g
negligible in the small region:
-
The equation of continuity is expressed by eqn (3.5.4), and eqn (3.5.5)
is derived by combining eqns (3.5.3) and (3.5.4):
div (G g) = Qrn (3.5.4)
(3.5.5)
The functional for eqn (3.5.5) is written as eqn (3.5.6) in the cylindrical
coordinate system assuming axis symmetry:
2~ det
and (r" Zj), (r2' Z2), and (r3' Z3) denote the coordinates of the nodes 1,2,
and 3.
In order to derive the global finite element equation on gas flow, eqn
(3.5.6) is integrated after substitution of eqn (3.5.7). Equation (3.5.10) is
derived from the equation thus obtained together with eqn (3.5.9) for
minimizing X:
o (3.5.9)
(3.5.10)
where superscript e indicates a local finite element. The signs [ ] and ( )
designate matrix and vector, respectively. The matrix and the vectors in
eqn (3.5.10) are defined as follows.
Vector for the pressure of nodel points (P)":
(p)e = (Ph P2 , P3 )T
BjB j + CjC j B jB 2 + C jC 2 B jB 3 + C jC 3
[H]e aoV B 2B j + C 2 C j B2B2 + C 2C 2 B2B3 + C 2C3
~~+~~ ~~+~~ ~~+~~
where
(r j - 7)2 + (r2 - 7)2 + (r3 - 7)2
(r j - 7)(Zj - z) + (r2 - r)(z2 - z) + (r3 - r)(zj - z)
=
r = (r j + r2 + r3)/3
=
Z = (Zj + Z2 + z3)/3
V = TTr/2~
218 BLAST FURNACE PHENOMENA AND MODELLING
Inflow vector (Fs)": suppose that the gas flows in with mass velocity
qrn between the nodes i and j; thus we have:
2rj + rj
o
A set oflinear algebraic equations with respect to the nodal pressure is
obtained as given by eqn (3.5.11) by summing eqn (3.5.10) for the whole
range:
[H](P) - (Fs) - (Fb) = 0 (3.5.11 )
The pressure gradient can be obtained by differentiating eqn (3.5.7)
and substituting it for eqn (3.5.3), which gives the following equation:
IGgrt
Ggz\
e = -a'
0
IOP/ort
op/oz\
e = _ ~IB'
2.6. C,
B2 B3 t (p)e
C2 C3 f
(3.5.12)
This equation gives the distribution for the mass velocity of gas. Since a o
depends on the velocity vector Gg, the same computation is repeated
after the recalculation of a o on the basis of the previously computed
value of Gg • The computation is assumed to be convergent if the
maximum change in the mass velocity before and after the trial
computation becomes smaller than a specified value (10- 4 in relative
error).
TABLE 3.5.1
Operating Conditions of the Blast Furnace28
In the gas flow analysis, both the computation condition and the
structure of the bed are given on the basis of the operating conditions
listed in Table 3.5.1 and of the profile shown in Fig. 3.5.1 for a large blast
furnace operating in Japan. Characteristic values for the four different
kinds of elements which are used for numerical computation are given
in Table 3.5.2 and the essential conditions for the numerical computation
are summarized in Table 3.5.3.
TABLE 3.5.2
Properties of the Layers28
35
30
OC 1=
25 73.4°
20
E 15
N
10
o 5 10
r (m)
Fig. 3.5.1. Profile of the blast furnace. 28
tv
TABLE 3.5.3 tv
0
Characteristics of the Case Studies for Gas Flow Analysis28
30
25
20
15
E
N 10
5
-
... . , ....
.::: ;;: -: ~
.....
o
I I I
o 5 10
rIm)
Fig. 3.5.2. Gas flow vector (G, mass velocity of gas) computed for case (1).28
Compared to case (I), case (3) shows significant preferential flow in the
central core at the top of the bed. These results indicate that the
difference in permeability of the layers and the inclination angle of the
burden principally cause nonuniform gas flow in the upper part of a
blast furnace.
For the approach to the real internal state of the working blast
furnace, cohesive and raceway zones were assumed in cases (4), (5) and
(6). Figure 3.5.4 gives the shape and position of the cohesive and
raceway zones for case (4). Case (5) has the same bed structure as case (4)
except that the cohesive layers contact the furnace wall (termed the
cohesive zone 'roof), while case (5) does not have such wall contacts of
cohesive layers. The bed structure for case (6) is also similar to that for
case (4). In case (6), however, the dead zone occurs which has high
resistance to gas flow. Figures 3.5.5 to 3.5.7 show the computed results
for case (4), indicating that the velocity vector is principally governed by
the bed structure. It is easily understood from the figures that the
cohesive layers playa role as gas distributor.
GLOBAL FORMULATION 223
35 ... 5(kg/m Zsl
30
25
20
15
E
N 10
o
I I I
o 5 10
rIm)
Fig. 3.5.3. Gas flow vector (G, mass velocity of gas) computed for case (3).28
35
30
25
20
15
E
N 10
0 5 10
rim)
Fig. 3.5.4. Schematic representation of the bed structure and finite elements for
case (4).28
224 BLAST FURNACE PHENOMENA AND MODELLING
4- S(kg/m 2.s1
35
III!,
30 II I!\'r'/I\
[","':""',
,!, ',', ~: ",', \.
I': ~'j r ~ ',', \.
20 ~!~~:~~:!,:,
E
15
~l 1r«;\
:13j
N 10
ii!!fifi//
.....
:: ~ :~~:
" ''-
5 ~~~
·
·..··. . , ....
' ,.
.. .,.,, ..
o ·.
I I I
o 5 10
rIm)
Fig. 3.5.5. Contour lines of Gz computed for case (4).28
Figure 3.5.8 shows the pressure distributions along the furnace wall
for cases (4), (5) and (6) as shown in Table 3.5.3. No difference was found
in the upper part of the cohesive zone, but a small deviation was
observed in the lower part of the zone. This means that the change in
bed structure affected the gas flow only upstream of the change.
Figure 3.5.9 shows a different bed structure, where the cohesive layers
were assumed to be wider. Computed results corresponding to this bed
structure are represented in figs 3.5.10 and 3.5.11. Compared to case (4),
this case gave exactly the same flow pattern downstream of the cohesive
layers, but significant influence of the cohesive layers upstream.
Increase in the volume of the cohesive layers may therefore lead to
increase in pressure loss. Figures 3.5.12 and 3.5.13 illustrate computed
results for the case of higher top pressure in the same bed structure.
These results show almost the same flow pattern, but considerable
decrease in pressure loss.
GLOBAL FORMULATION 225
35
30
25
20
15
E
1.0
N 10
5
0.1
0
I
0 5 10
rIm)
Fig. 3.5.6. Gas flow vector (G, mass velocity of gas) computed for case (4).28
35
0.167
30
25
20
15
E
0.226
N 10 0.230
5
0.234
P(M Po)
o
I [ I [
Shaft
0.25
I ~ II a
Cohesive lie,s (Cases 4 and 6)
02
<- Wall ""-;;._~-:-
.:__:-::---<
__
o
c.. 023
::::0: .
.-- .. ~:....,..
35
30
25
20
15
E
N 10
0 5 10
r (m)
Fig. 3.5.9. Schematic representation ofthe bed structure and finite elements for
case (7)?8
GLOBAL FORMULATION 227
3S
111:!:\t
30
"~~!! :,:, lL,
l\',',I!I\I,
2S
20
15
E
N 10 J r.- .... ';
5 ,!!HH~
o
o 5 10
r (ml
Fig. 3.5.10. Gas flow vector (G, mass velocity of gas) computed for case
(7).28
o 5 10
r(ml
35
I I I! ~ !'
30 :~~~\~!!/
,,:, I~!!~\
, 't I ~, ~ I : ••
i\~\~I\
25
20
Ir::r:::'
15
.5 N
10
i
~L.
5 l [:;~ :~iti
o 5 10
r i m)
3S
0.275
30
2S
20
.--,_.___, 0.314
IS
E
0.324
N 10
1---_..-< 0.333
0.338
5
PIMPo)
o SID
rim)
-
(3.5.13)
Boundary 8 2 :
the tuyere):
q3 -
= -n K~V(Ts)
Heat flux is proportional to the temperature difference
--
(heat loss through the wall):
-n K~ V(Tg - Ta) hg(Tg - Ta)
-n K~V(Ts - Ta) hs(Ts - Ta)
The temperature distributions for gas and solid can be computed by
solving the finite element equations derived from eqns (3.5.l3) and
(3.5.l4) according to the Galerkin method together with the above
boundary conditions. Both the finite elements and the interpolation
function for the temperature equations are the same as for the gas flow
analysis. Accordingly, the temperature distributions in a local finite
element are expressed as follows:
Combining these equations with eqns (3.5.13) and (3.5.14), and also
with the boundary conditions, weighted residuals are obtained
according to the Galerkin method. Equations (3.5.l5) and (3.5.16) are
230 BLAST FURNACE PHENOMENA AND MODELLING
derived by equating the sum of the weighted residuals for each term in
eqns (3.5.13) and (3.5.14) to zero:
- JrQgAj dv = 0
v SI ~
(3.5.15)
(3.5.16)
- - -- -
summing eqn (3.5.17) over the whole range:
[Hij](T i) + [F ij](T i) + (b j) =0 (3.5.18)
where i and j are changed from 1 to the number of the nodal points.
Since the terms in regard to physical properties of gas, liquid and
solid are nonlinear with respect to temperature, numerical computation
is conducted iteratively. The computation is considered to be in
convergence if the maximum temperature change before and after one
iterative computation becomes less than a specified value (10- 3 relative
change).
In order to solve the heat balance equations given by eqn (3.5.18), the
solutions not only for gas flow but also for solid flow are required. Here,
potential flow is assumed for the solid movement. Therefore the
equation of motion is expressed by eqn (3.5.19) and the equation of
GLOBAL FORMULATION 231
-
continuity which is also necessary for the flow analysis on solid is
represented by eqn (3.5.20):
-
- grad (c/>s)
div (V s)
= V./a s
= Vsm
Solid flow in the blast furnace was investigated by Nishio et al. 138 on
the basis of the data obtained by dissections. Their results support the
appropriateness of potential flow in the stack region. Further research,
however, is required on solid flow in the lower part of a blast furnace.
3.5.4. Computed Results on the Simultaneous Gas Flow and Heat Transfer
A set of computed results obtained by the simultaneous analysis of gas
flow and heat transfer are shown in Fig. 3.5.14. In the analysis, the same
configuration of finite elements for gas flow analysis was used.
However, a dead zone for solid flow was set up additionally as
illustrated in Fig. 3.5.14(a). It should be noted that allowances have not
been made for the heat sink accompanying the fusion of iron ore and
also the heat generation associated with the combustion of coke in the
raceway region for the case shown in Figs 3.5.14, 3.5.17,142 and 3.5.18. 143
These results, however, show the significant interaction between gas
flow and heat transfer. Figure 3.5.14 gives the computed results for
uniform particle size and uniform voidage in both the ore and coke
layers. The flow vectors for gas and the pressure distribution illustrated
in Fig. 3.5.14(b) and (c) demonstrate essentially similar patterns to the
results obtained by gas flow analysis alone. During computation of
simultaneous heat transfer and gas flow, the temperature distribution
computed successively was used as the temperature distribution
required for the computation of the physical properties such as density,
viscosity, heat capacity and so on. Figure 3.5.14(d) gives the flow vectors
for solid movement showing that the movement is principally governed
by the furnace shape. This is the behavior of solid particles which are
governed by the potential flow assumption without consideration of the
effect of gas flow and temperature distribution, and where the only solid
disappearance is through discharge at the tuyere. Figure 3.5.14 (e) and
(f) illustrate that the temperature distributions of the gas and the solids
are represented by almost uniform profiles in the upper part of the
cohesive zone, while in the lower part the temperature distributions are
governed principally by the shape of the cohesive zone. Accordingly,
232 BLAST FURNACE PHENOMENA AND MODELLING
35 35 "Slkg/m 2 s) 35
III!~'
30 3D \'\\,1 1, 30
)))/~.",!\
)))\~~(,
25 25
))~M;' 25
II 11\\
1\\\\\
11\\\\
~li~
20 20 20
15 15 15 0.235
E
E E
11/1'mIl' '
NIO :; 10 -;; 10
.... n~,'-~
Irm~m
5 5 5
PIMPal
o 0 0
o 5
rim)
10 0 5 10 0 5
rim)
10
rim)
(a) Fonite element r"presen- Ib) Gas flow vectorlG 'mass Icl isopressure lines
lotIon velOCity of gosl
35 35 35
30 30 30
25 25 25
20 20 20
15 15 15
~ E
N 10 -;; 10
5 5 5
TgIK)
o 0 0
o 5 10 0 5 10 0 5 10
rim) rim) rim)
I d I Sol id ftow vectorlV : lin- Ie) isother ms of go s (I) Isotherms of solid
ear velocity of solId)
Fig. 3.5.14. Results obtained by the simultaneous analysis of gas flow and heat
transfer in the blast furnace (uniform size and voidage in ore and coke layers,
respective! y).
GLOBAL FORMULATION 233
10
IAI Type 139,140
141
E
8 \, IBI Type
0
I
"-,
iii
OJ
E
6
"'- "-, Coke
"
-0
~
4
--------~~----
'\
Average
---
'"
'§
--
CL
2 '-
~--~--=-
Average
--..::::.. - -
---
- ---
IAI Type
\ IBI Type
0.55 '\
'\ ,
'" Coke layer
-'\----~~,~-=- ----.=-
Average
c
Q
u 0.50
g
-0
6
>
. . ___ _
Ore layer
35 35 -5IKG/M'S)
_OAE
--COKE
30 30
25 25
_ 20
I:
N 15 N 15
COHESIVE
10
ZONE
10
5 5
DEAD ZONE
fDA SOLID
o o
o 5 10 o 5 10
RIM) RIM)
IA) fINITE ELEMENT (8 ) GAS fLOW VECTOR
REPRESENTRTION (G:MASS VELOCITY
Of GAS)
35 P 35
30 30
25 25
_ 20 _ 20
I: I:
N
15 0196 N 15
0.201
0.206
10 10
5 5
0 0 - 0.1!'
o 5 10 o 5 10
A 1M) A (M)
(C) ISOPRESSURE LINES (0) CONTOUR LINES Of
AVERAGED MASS
VELOCITY Of GAS
GLOBAL FORMULATION 235
35 TG(Kl 35 T5(K)
30 30
25 25
_ 20 _ 20
=
N 15
s:::
N 15
10 10
1600
700
1750
5 1795 5
0 o
o 5 10 o 5 10
R (Ml R (M)
Fig. 3.5.17. Results computed from the simultaneous analysis of gas flow and
heat transfer (particle size distribution, type (A)).
the result shows that the shape of the cohesive zone dominates the gas
flow pattern and the gas flow markedly affects the temperature
distribution.
Regarding the radial distribution of temperature, the computed
results show an almost uniform distribution in radial direction in the
shaft region, whereas actual measurements of temperature in operating
blast furnaces and dissection investigations 134 often gave significant
nonuniformity in temperature distribution. Since bed structure exerts a
great influence not only on gas flow but also on the temperature
distribution as already described, radial distribution of the particle size,
as well as the void fraction distribution, may play an important role for
the internal situation of a blast furnace.
According to the paper by Yamada et al., 139 the void fraction depends
on the particle size and its distribution in sinter and coke beds,
respectively. Empirical equations were derived by them representing
the relationship between void fraction and particle size on the basis of
the experimental data. Simplified expressions were obtained from the
236 BLAST FURNACE PHENOMENA AND MODELLING
35 35 - 5(KG/M' S)
ORE
COKE •\~!!,
30 30 ""I,
~))~~~~'I
)))\))(,
25 25
)))M\
))~)\'\I
\\\\(\1
\\\\\\1
_ 20
-
1\\1\\\
20 11\ \ \ \ \ \ .
III \\ \\\
I: I: lr\\\
IS ~~4~\
l rIW-f!~'
N N
15
10 10
5 EWAY
AD ZONE
SOLI D
5
i!"'!;ffi
o 0
0 5 10 0 5 10
R (M I R ( M)
(A) FI NIT E ELEMEN T (8) GA5 FLOW VEC TOR
REPAESEN TATION (G:MASS VE LOC I TY
OF GAS)
35 P
30
25
_ 20
I:
N
15
0.196
0.201
10 0205
o 5 10 o 5 10
R (M I R (M)
(C ) 150PRESSURE LI NES (0) CONTOUR LI NES OF
AVERAGED MASS
VELOC I TY OF GAS
GLOBAL FORMULATION 237
3S TG(K) 3S TS(K)
30 30
2S 25
~ 20 ~ 20
.-
:E:
~
N IS N IS
10 1600 10
170
175
780
8 160
170
~175
8
5 1795 5 1780
1795
0 0
0 5 10 0 5 10
R (M) R (M)
(E) ISOTHERMS OF GAS IF) ISOTHERMS OF SOLID
Fig. 3.5.18. Results computed from the simultaneous analysis of gas flow and
heat transfer (particle size distribution, type (B)).
equations for estimating the void fraction distribution for the averaged
size of sinter and coke as described below.
For sinter layer:
(3.5.21)
For coke layer:
e = 0·153 log de + 0·724 (3.5.22)
where do and de have the dimension of m.
Regarding the radial distribution of particle size, it is very difficult to
measure the size distribution of particles at the top of an operating blast
furnace. Some observed data were, however, reported by using a full-
scale charging model without gas flow or by sampling from a real blast
furnace, also without gas flow, at the time when it was packed just before
starting up. The two types of observed distribution of particle size are
shown in Fig. 3.5.15. 142 The average diameter for both distributions is
shifted to the value specified in the figure. Figure 3.5.16 143 gives radial
distributions of void fraction computed from eqns (3.5.21) and (3.5.22)
for the particle size distribution shown in Fig. 3.5.15.
238 BLAST FURNACE PHENOMENA AND MODELLING
Figure 3.5.17 and 3.5.18 demonstrate the internal state of the blast
furnace computed from the mathematical model applying both (A) and
(B) type particle size distributions. In both cases, the same bed structure
and same finite element configuration were used. Each finite element in
the same layer was, however, assigned a different permeability due to
different particle size and void fraction. This gives rise to marked
nonuniform gas flow even in the shaft region as shown in Figs 3.5.17 (B)
and 3.5.18(B). Figures 3.5.l7(D) and 3.5.18(D) provide a clearer
representation on this nonuniformity of gas flow where, in Fig. 3.5.18(D),
preferential flow of gas is found in the central zone in the shaft region
and, in Fig. 3.5.18(D), the intermediate region has higher resistance for
gas flow caused by size distribution. Therefore the main flow of gas is
still in the central region but a considerable gas flow occurs in the
peripheral region. The temperature distributions for gas and solid are
illustrated in Figs 3.5.17 (E) and (F), and Figs 3.5.18 (E) and (F) show
the corresponding gas flow patterns. These results are quite realistic in
terms of real furnace operation compared to the results obtained for the
case of uniform size distribution given in Fig. 3.5.14. It can therefore be
inferred that the temperature profile is governed mainly by the gas flow
distribution and that the bed structure, including size distribution of the
particles, is a predominant factor governing gas flow. It may consequently
be understood that the charging method and the profile of the cohesive
zone are the principal important factors for estimating the static
performance of the blast furnace.
and thereby to make clear the functions of the cohesive zone for blast
furnace operation, and further to investigate the desired profile of the
zone in furnace operation. 40 It has become clear from the results of an
investigation during the test operation of a blast furnace 152 that the
desired profile of the cohesive zone is such that the inside boundary of
the zone (i.e. the starting line of melting down) should be as close as
possible to the dead man of the furnace in order to optimize the furnace
stability, reducibility and thermal efficiency.
For analyzing blast furnace operation in terms of the cohesive zone,
it becomes necessary to estimate the profile of the zone and the gas flow
distribution in operating furnaces. However, at present a mathematical
model for estimating the profile of the whole cohesive zone is
unavailable. Therefore the aforementioned mathematical model will be
modified to obtain a model for estimating the profile of the cohesive
zone and the gas flow distribution at each coke slit with the use of gas
pressures at the wall of the furnace (hereinafter referred to as shaft gas
pressures). The results will be checked against data obtained in blast
furnace operation, and the blast furnace operation will be analyzed
using the estimated results.
profile of the cohesive zone can be obtained from the shaft pressure
distribution.
For obtaining the profile of the cohesive zone based on the above
principle, two methods are available:
(1) Method using a mathematical model (static pressure model)
(2) Method using the analogy of gas flow to electrical conductivity
with the use of electrically conductive paper
In these two methods, when the whole profile of the cohesive zone is
given, both the volume of gas distributed to the coke slit layers and the
pressure distribution at the inside and outside boundaries of the
cohesive zone can be obtained.
Methods (1) and (2) differ in the following respects. Using method (I),
the profile can be changed relatively easily, and the error between
calculation results and data acquired by actual measurement can be
verified readily; further, the relevance of the equations available for
estimation can be improved with experience. On the other hand,
method (2) is time-consuming since the profile of the cohesive zone has
to be measured by physically making the zone configuration with
conductive paper. However, it is possible to easily understand the gas
flow and pressure distributions in a locally unusual profile which is
difficult to express by numerical equations, e.g. a profile with no zone
apex or root.
This section takes method (1) as the main subject, and a few remarks
are also made about the principle of method (2).
Figure 3.6.1 shows the principles associated with measurements
made using conductive paper,153. 154 where (a) is a method available for
obtaining the pressure distribution and (b) for obtaining the gas flow
distribution.
In the pressure model the cohesive layers are represented by cutting
out the conductive paper, whereas in the flow model the conductivity is
raised by applying a silver paint. The gas flow lines and pressure
distribution can be obtained by measuring the voltage distribution
while applying a constant voltage to the conductive paper. However, it is
clear that this measurement is made on the basis of two-dimensional
potential flow, and this is appreciably different from the actual flow
in a three-dimensional situation.
It is to be understood from Fig. 3.6.2 that when comparing profile E,
where the inner side profile has protruded inward, with the profile of the
cohesive zone A, the ratio of the pressure drop in the lower part of the
GLOBAL FORMULATION 241
131
02 04 0_6 08 I0
p . I-I
X Rb Profi le
H'b 1.73
A-E
W, 0. 17
0.32 A
Wb
0.67 £
Fig. 3.6.2. Relation between profiles of cohesive zone and pressure distribution.
Figure 3.6.3 shows a calculation flow diagram for computing the way
in which gas is distributed to the coke slits at the cohesive zone once the
profile of the cohesive zone is provided.
Usually pressure loss is determined by the gas flow rate. However, in
this model it has been taken that the flow rate depends on the pressure
loss. That is, gas flow is produced at the coke slit layers according to the
difference in pressure between the coke column inside the cohesive
zone and the lumpy zone.
The calculation is performed as follows using a trial-and-error
method. First, a certain proportion of the gas flow is allocated to the
lowest coke slit layer, whereby pressure at A-B, A-a and a-b can be
obtained.
Gas flow rate at the second-stage coke slit layer from the bottom may
be obtained from the difference in pressure between Band b with the
above assumption. The gas flow rate at the next coke slit layer can also
be obtained in a manner similar to that used in the above discussion.
During iterations in which pressure inside the cohesive zone
becomes lower than the pressure at the same level in the lumpy zone, the
calculation is suspended and the flow rate has to be set again to a new
value at the bottom stage of the calculation.
GLOBAL FORMULATION 243
B.---==:!lJ
Fig. 3.6.3. Schematic diagram and calculation flow chart of gas volume rate
r,
distribution by cohesive zone (C~, C position and thickness of cohesive layer;
PA, Pdp PLu, pressure in front oflowest coke slit, at dropping zone, and at lumpy
zone; Pn , pressure at next coke slit; lJ.Pi, pressure drop at i-th coke slit; Vb, lowest
coke slit gas volume rate; V", coke slit gas volume rate; Vd, calculated total gas
volume rate; VT , total (bosh) gas volume rate).
244 BLAST FURNACE PHENOMENA AND MODELLING
Burden surface
(TOP gas temperature)
softening-
Lower level of
(IOOOOe)
apex
Inner side of
softening - melting
zone (iSOOOC)
Fig. 3.6.4. Determination of the profile of the softening-melting zone and gas
temperature in the furnace.
GLOBAL FORMULATION 245
at the tuyere centre line. The inner and outer boundaries of the zone are
assumed to lie at l800°C and 1000°C respectively. The gas temperature
in the intermediate regions is linearly approximated according to the
height. Temperatures at the inner and outer boundaries of the cohesive
zone are determined based on the values calculated by another
mathematical modeU 8 These temperatures will be re-defined in future
when the softening and melting properties of burden are made clear.
(4) The gas viscosity is kept at a fixed value regardless of gas
composition and temperature. Gas density is also maintained at a fixed
value irrespective of gas composition, and change by gas temperature
only is taken into account.
(5) The gas pressure at the tuyere center is set to 0·9 times the blast
pressure.
(6) Taking account of the volume change of burden as a function of
height, the bulk densities of ore and coke are provided by the following
equations according to the dissection studies of the Kukioka No.4 blast
furnace: 145
Po 1·90 + 1·3x (3.6.l)
Pc 0-45 + 0'3x (3.6.2)
where Po and Pc designate the bulk densities (tlm 3) of ore and coke, and
x is the dimensionless height from burden surface to tuyere center.
divided according to the ore and coke bases. Thus the following
parameter adjustment sequence is fixed: height oflower level of root_
Height of origin - Inside radius at origin _ Height of upper level of
apex - Height of upper level of root - Outside radius at origin.
With the first parameter changed, calculation is continued while the
sum of squares of the difference between the calculated and the
measured values is decreasing, and when the sum commences to
increase the calculation is transferred to the next parameter. On
completion of the calculation, made by changing the final parameter,
the profile of the cohesive zone which gives the minimum value for the
sum of squares of the difference between the calculated and measured
values is found. Mter that, a second calculation is made by changing
from the first parameter once again with this profile adopted as the
initial value. As a result of the second calculation, the profile of the
cohesive zone which yields the minimum sum of squares of the
difference can be obtained. This minimal sum of squares of difference is
taken as the minimum value in the calculation process, and no
restrictions are placed on its absolute value.
The profile of the cohesive zone obtained by the above procedures is
not computed through every alteration sequence of the five parameters,
and therefore it cannot be said, in the strict sense, that the sum of
squares of difference is kept absolutely at a minimum. However, it may
be considered to approximate a very exact solution in view of the fact
that the results of verification of the model stated later are satisfactory,
and the procedures described above take account of savings in
calculation time.
0
- pressure distribution in
\ the case that gas
2 \
\ temperature is decided
\ by simple linearization
\
4
\ ---- pressure distribution in
6 \ the case that cold gas
\ flows
\
E 8 \ • Measured shaft pressures
\ used in the mode I
.
10 \
CD \ Measured top pressure
> \
.!! 12 \
....u
-
\
\
0 14 ~
II> \
\
-
16
E \
...
0
18
\
\
\
-
CD \
u
c 20 \
0 \
II>
·0 22
24
26
28
dropping zone. Slightly above the root, however, gas flows towards the
wall through the bottom coke slit and this results in a sudden pressure
drop.
Based on the following three points, it was judged that better results
are ensured in the case where no gas flows through the dead man:
(1) Only a slight difference between the calculated and measured
shaft gas pressure at the bottom level is found for the assumption
of zero gas flow through the dead zone.
(2) Since the radial gas temperature distribution obtained with a
shaft probe shows a low temperature at the wall, it is guessed that
a u
o -pressure distribution in the
case that gas doesrft flow
2 1000 CD
~
through dead man
;:)
- --Pressure dist ribution in
4 500 "0
~ the case that gas flows
CD
0- through dead ma n
E
6
...
CD • Measured shott pressures
used in the model
E II>
8 o ® Measured shaft pressure
<!)
at the lowest level
CD 10
>
..!
12
....u
0
14
Vi
E 16
...e 18
CD
u
r::
0 20
Vi
0
22
--------- ...
.... ...
,,
,
24 \
\
26 ,
I
I
\
\
28 \
\
Fig. 3.6.6. Effect of dead man on the profile of the softening-melting zone.
GLOBAL FORMULATION 249
.
\ linearization
E \
\ Measured shaft pressures
.
10
\ used in the mode I
Qi \
>
II> 12 \
\
\
.\
.>0:
0 14
~
II>
16
-
E
...0
18
Q)
0
c:
c 20
.~
0
22
24
26
28
the exponential function given by eqn (3.6.3) taking the gas temperature
distribution obtained with the top probe as the initial value. This case,
which takes the averaged radial temperatures calculated from the
equation at each vertical level, is compared with the simple linear
temperature distribution given earlier in the figure.
(3.6.3)
where Tg designates gas temperature caC), db d 2 and d 3 are constants,
and z is the distance (m) from the burden surface.
It can be said that the difference between the calculated and
measured values of shaft gas pressure is made smaller by predicting the
gas temperature more accurately using the above equation, and the
estimation accuracy of the profile of the cohesive zone has thereby been
improved. However, since there is no substantial difference in the
estimated results of the profile, it is preferable to use the simple
temperature prediction method.
8
E
10
Q)
>
Q)
12
-
.>0::
()
o 14
I II
E 16
o...
'0-
Q) 18
-
()
J::
o
I II 20
o
22
24
center wall
Fig. 3.6.8. Comparison of the results estimated using the model with those from
another mathematical model.
_ 0 50 . . - - - - - - - - - - - - - - ,
-~
0-
~
".&>
..
E! ~ (a )
'&e ( b)
1! ..
.~ e /.
'50.. 60
0.0.
~. ..
o
X 40 :.
--
Q.
.. 0. ~:
.c 0
.: =i
.. .
0:
"- "j
!' 0:."
30 .~.; 55
~ '0
" " /- ~.E
~o..&>~ :s-g
: .~
E 0 "o 0
0:
20 '--------""--_-'-_ _l-.._......J ~"Oo 50 '---_---L_ _- ' -_ _'---_--'
50 60 70 80 90 0 ~ 50 60 70 80 90
o '"
'" E Gas flow in Ih. peripheml region (Nm 3/s) Gas flow in Ihe peripheral region "(Nm3/s)
130,------------,
o
o ~-
-0
_0 \
i
0-
~ 60 ,-----------;(c-:C~) " ,,110
0: ~ <.>
5~ " 0
"00:
A-----..,-
~.~ g~
o
"0 "
.c 40 ---.--:~ • ~.
<.> - ~ CP 90
O.c
.~
-" "
.. 0 1;;-
-
..5 -
~ ~
~ e. ~
o ~
20 ~ 70
E~
-~ "~
2
8.1! o L-_---L_ _- ' -_ _' - - - _ - '
x. :;
E
~
;0
•
Al1aehed level of Ihermoeouples
2. 50 '--_...L.I..._ _- ' - _ - - '_ _- '
" -
E - 50 60 70 80 90 17 18 19 20 21
.... 0
Gas flow in Ihe peripheral region (Nm3/s) Dislane.of upper level of rool from slack level (m)
Fig. 3.6.9. Relation between the results estimated using the model and data
obtained with other instruments in the furnace"
volume of
droppi nil zone Cross section of co~e sli Is
ot inner side of softeni ng-
melting zone
110
(.) (a )
0
-
...
Q)
::J
100
...
.,
0
Q)
a.
-E
Q)
1/1
0
90
• .~
co
a.
0
~ 80
1300 1400 1500 1600 1700 1800
52
(b)
~
0
~
-
c:
0 50
• •
0 •
, •••
-
N
• • •
•
::J
• • •
48 •
1/1
0
•
co
0
(.)
46
1300 1400 1500 1600 1700 1800
increases, greater heat exchange between gas and solid occurs and, as a
result, the average top gas temperature decreases. However, the average
TJco in the top gas remains almost constant and this may be because
reduction does not occur below a certain temperature or because the
effect of radial gas flow distribution in the lumpy zone is equally as
important as the volume of the lumpy zone.
Analysis results, including those gained in the operational test of the
Kimitsu No.3 blast furnace with low fuel ratio in 1975, have revealed
that there is a favourable correlation between gas utilization ratio (TJ",)
and lumpy zone volume. It has been discovered that increasing the
lumpy zone volume greatly contributes to improvement in furnace
efficiency.
Figure 3.6.12 shows the relationship between dropping zone volume
and blast furnace operation. Since the quantity of heat transferred from
the gas to the molten metal becomes greater as the volume of the
dropping zone increases, the molten metal temperature rises and the
retention time of liquids becomes greater, thus resulting in an increase
in the Si content in the molten metal. The Si content in the molten metal
shows a fixed value for dropping zone volumes below a critical value,
and in this range the chief reaction is between SiO gas and metal at a
high rate. When the dropping zone volume increases beyond the above
range, the contribution to hot metal Si of the slag-metal reaction
becomes great. The mechanisms for these reactions are currently under
study.
It is to be understood from the description given above that the
volume of the lumpy zone is a useful index representing the thermal
efficiency and reducibility of the blast furnace, while the volume of the
dropping zone is a useful index for representing molten metal
quality.
It is found from Fig. 3.6.13 that the permeability resistance index, K,
in the blast furnace rises as the gas flow per unit cross-section of coke
slits at the inner side of the cohesive zone increases. It is surmised that
this is because the total cross-section of the slits reduces as the apex of
the cohesive zone becomes lower, and this results in an increase in gas
pressure.
K = (P~ - p?)/BG17 (3.6.4)
where P b and PI are blast pressure and top gas pressure (g/cm abs), and
2
.----.0
1540 r------------------------------------------------------,
( 0)
U
a
1530
.•
Q)
...,
~
:::s
rc
• •
• •
~
•
.~
Q)
1520
--.
D..
•
...,
E
Q)
...,rc •
Q)
E 1510
...,
0
:c
1500
500 550 600 650 700 750
0.45
*
...,
';;; ---.
Q) •
E
..., 0.40
0
.<:: •
•
C
...,
.~
c
- . •
,_ _ _ _ _ _ _ _ _ _ _ _ _ __eo_.
...,
Q)
0.35
c
0
u
.~
Vl
•
0.30
500 550 600 650 700 750
2.6 r - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
/
•
2.5
-
III
o
0'
o
><
a>
2.4 .1 •
"0
c:
2.3
.J:J
o
a>
2.2
....E
a>
0.. /.
~.
2.1
2.0
1.2 1.4 1.6 1.8 2.0 2.2 2.4
Fig. 3.6.13. Effect of gas flow per unit cross-section of coke slits at inner side of
softening-melting zone on permeability index of gas.
20 .---------------------------------------~
>-
0
"0 15
"'-
II>
Q)
• •
E
0-
0
10 •
....
0
+
0-
(/)
___________ .--------
>< 5
l~
If)
.-
OL---~--L-----~--~--~~~--~------~
. .
1.3 14 1.5 1.6 1.7 1.8
Fig. 3.6.14. Effect of the shortest distance between inner side of softening-
melting zone and dead man on descent of burden.
.1
Stagnanr zone
Ibl Movemenl af sound,ng
150.3.21
lal
Fig. 3.6.15. Successive slips in operational test of the Kimitsu No. 3 blast
furnace with low fuel rate.
~ 20 r-------------------------(-a--,)
.D
o •
><
CI)
a. .---~-------.,--~.~---.~.----
-
18
o •
o •
~~
.!! E 16
...
CI) ...
o.CI)
g.~
•
_ ~ 14
./
/
o
•
.~
.... II)
oC'"
.~~
!~. 12 L-_ _ _ ~ ____ ~~ _________ L_ _ _ _ _ _ _ _ ~ ______ ~
II) 20.------------------------;l~--~(-b~)1
>
o
I·
.D
o
><
CI)
a. 18
-
o
o • ••
~ ..... ••• •
./
16
.!! E
...
CI) ...
o.CI)
a. ....
C
/'
::::I
_ u
II) 14
-------
0
.... II)
oC'"
.~ ~
! ~ I~IOOO 12000 13000 14000 15000 16000
high coke base in Fig. 3.6.l6(a», the level of the apex is decreasing
despite a constant gas flow. This is supposed to be because of a delay in
the heating of ore inside the thick ore layer.
Further, when Fig. 3.6.l6(b) is prepared by taking only the data
enframed by the rectangle in Fig. 3.6.16(a), it is found that, the larger
the kinetic energy of the blast flowing through the tuyere (hereinafter
referred to as a tuyere energy), the higher the level of the apex even
though the gas flow is the same. This is because the depth of the raceway
becomes larger and more gas flows toward the central region as tuyere
energy increases.
Thus, the greater the bosh gas volume per tuyere, the lower the level of
the root, as shown in Fig. 3.6.17(a). The reason for this is the same as the
--.
above, namely that, the greater the gas flow, the deeper the raceway and
~ ~
••
•
1\.
1\ , :----
-
,..
Q) 2.0 1\
J \
'0;
Data in high coke base __ - - i
1.0 '---_ _--'---_ _--'-_ _'-=L::..-"--_-L.
-
(0 0
-------
0 o~~~~
_ _----'=--_ _...L.-_ _.....J
'0
-
o~
~ E (b)
":--.>----
o ~ 3.0
Q)
>
-Q)
~
Q)
-c:
Q)
... -..
-- -------------
:p
..
(J 2.0
----.--...-------
~ Q)
,...,
o ~
0;
:c Q)
1.0 ' - - - - - - ' - - - - - - ' - - - - ' - - - - - - - - - '
13000 14000 15000 16000 17000
'" 0>
._
Q) .0
::c c Kinetic energy of blast (kg' m Is )
Fig. 3.6.17. Effect of bosh gas volume and kinetic energy of blast on the level of
the root.
262 BLAST FURNACE PHENOMENA AND MODELLING
the more gas flows towards the central region. As bosh gas volume
decreases, the raceway depth becomes less and this results in more gas
flowing in the peripheral wall region. Consequently the root is melted
more rapidly and the level of the root goes up.
Further, when the ore base per charge is high (encompassed by short
dashes as data in high coke base in Fig. 3.6.17(a)) despite gas flow being
the same, heat transfer to the root interior is delayed and the level of the
root is lowered. In addition, when Fig. 3.6.17(b) is prepared by taking
only the data encompassed by the rectangle in Fig. 3.6.17(a), it is found
that, the greater the tuyere energy, the lower the level of the root, even
though the gas flow is the same. The reason for this is that more gas
flows toward the central region when tuyere energy is higher and gas
volume in the peripheral region decreases. Also, for operation with low
fuel rate, the volume of gas for melting the root decreases and, as a result,
the root level lowers.
The mechanism of descent in the apex and ascent in the root for
decreased production operations, based on the above results of
investigation, is as shown in Fig. 3.6.18. However, the extent of the
IEer.a.. in production
n
Oecreo.. in volume Of} ... Decreall in volume of gal
bosh gas per un it croll section of
y
the furnace
1
Decrease in kinetic
energy of blaB' I Oecreo.e in volume of I I ,,~.,'.. '" .~~
~I reduction in volume
'"~
of
tuyer.
I
bosh gal per
r race way
Acceleration
Descent in apex I
Fig. 3.6.18. Change of the blast furnace condition with a decrease in the
production of the furnace.
GLOBAL FORMULATION 263
change in the levels of the apex and the root differ according to whether
reduction has occurred through change in tuyere energy, gas flow per
unit cross-section of the furnace, and bosh gas volume per tuyere when
bosh gas volume decreases owing to operation with decrease in
production, ore base per charge and change in 'fuel rate.
Also, with regard to blast furnaces having the same inner volume, it
can be said that the rate of change in the levels of the apex and the root
for decreased production operations is less in a blast furnace with fewer
tuyeres or a smaller belly diameter.
in ut variables out ut
Volume flow rate
Chemical compositions (Burden) (Top Gas)
Physical properties. Temperature
(Diameter ,DensitY,etc.) Compositions
(State variables)
( Parameters)
Temperature
Geometric profile 'Heat exchange
. 1--- Compositions
Rate parameters
'Heat loss. Packing condition
in ut variabl es out ut
TABLE 3.7.1
State Variables in this Model
(a) Reduction of iron oxide by the gas: Rt, Ri, Rj, Rt (kmol/ml . h). An
unreacted core model with two reaction interfaces is adopted for the
reduction of iron oxide by the gas as follows:
R*1
ITO
a ( ----
P)
UPl·X22 - UP2 ·X12
(i = 1,3)
o 22.4R T pO X ll X 22 - X l2 X 21
1 TOP)UP2.XII-UP1.X21
R*1 a (----
o 22.4R T pO X ll X 22 - X l2 X 21
(i = 1,4)
TABLE 3.7.2
Transport Phenomena in this Model
Reactions
R(: Fe203 + CO _ 2FeO + CO2
R1: Fe203 + H2 - 2FeO + H 20
Rj: FeO + CO _ Fe + CO 2
Rt: FeO + H2 - Fe+H20
Rt; FeO + C _ Fe+CO
Rt: HP + CO - H2 + CO 2
Rr: C + CO2 - 2CO
Rt: C + HzO - CO + H2
R~: Evaporation of moisture
k
fi
= Di(2
do
+ 0·55 Reog 5S CgO.333)
DsF = k et:;(Tj296Y75
Dsw = ket:~T,/296)175
(k e = 0·0677 for CO reduction and 0·0298 for Hz reduction)
k HW. CO = 20100exp(-14000/RTs), k HW. Hz = 107 exp(-30000/RT.)
k WF . CO = 2600 exp(-14 OOO/RTs), k WF . Hz = 106 exp(-30 OOO/RTs)
Rt = ak6
1
( 22-4R Ts pO
ro P)2 (YCOYH20 - Yco:J!H/K6)
268 BLAST FURNACE PHENOMENA AND MODELLING
38 .7 PgUgCg a
Re0-4
g
GLOBAL FORMULATION 269
where Pgis the density, cgis the specific heat coefficient of gas and Reg is
the Reynolds number. Here a is introduced to correct the heat exchange
parameter in the case of the existence of liquid phase as follows:
Heat capacity of coke and un melted ore
a = Heat capacity of coke, un melted ore and liquid
(h) Heat loss coefficient: hw (kcal/m2 . h . DC). The heat loss through the
blast furnace wall proceeds in proportion to the temperature difference
between the inside and outside of the wall. The coefficient of heat loss is
estimated as follows:
h = kb
w lb
where kb (kcal/m· h . DC) is the heat conductivity of the lining brick and
lb (m) is the thickness of the furnace wall.
Here the time dependent term in the differential equations for gas can
be neglected because of the short passing time of gases through the blast
furnace:
oYg _ I
;;- - ~ fg(Yg , t, z) (3.7.2)
uZ ug
On the other hand, the differential equations for solid may be
rewritten in the form of total differential equations since they have a
unique solution as follows:
dYs = oYs dt + oYs dz
at oz
Therefore eqn (3.7.1) for solid can be transformed into a set of
ordinary differential equations as follows:
dYs dz
dt = fs(Y" t, z) and dt = Us (3.7.3)
270 BLAST FURNACE PHENOMENA AND MODELLING
TABLE 3.7.3
Input Variables in this Model
In this way the differential equations for gas and solid states may be
written as follows:
d
dt Pbe =
Liquid ratio: rl
Temperature of solid: Ts
d 1
dt Ts = Phe~Yn(dTs' csn/dTs) + Phe~ Yn.(dTs· csn,/dTs)
- Ts(:~:; cn~mk,n
n k
. R~ + ~ cn,~mk,n" R~)l
k 0 1
~
Position: z
dz
Us
dt
Descending velocity of solid: Us
Gas temperature: Tg
- Tg~Cl'
1
~mk,l
k
'R~lJ
Gas pressure: P
respectively, D (m) is the diameter of the blast furnace, e is the void ratio
of packed bed, Reg is the Reynolds number, and gc is the gravitational
conversion factor.
3. 7.1.4. Calculations
In solving the differential equations it is convenient to rewrite eqns
(3.7.2) and (3.7.3) in finite-difference forms. Here, the space difference
(Az) and the time difference (At) are given as follows.
The content of the blast furnace is divided into finite layers as small
as the space difference. One unit layer is made of burden and coke
charged at the same time.
The time difference is evaluated such that the blast rate over this time
supplies the necessary quantity of oxygen for the consumption of
carbon in the unit layer at tuyere level. Although this is about 10 min or
so, it may be subdivided into a half or a quarter of the required time
when it is too long to obtain accurate simulation results.
At the start of the calculation, the solid state variables must be set as
an initial condition. The boundary condition for gas at the tuyere level
and the time difference are calculated from the input blast conditions.
Then the differential equations are integrated from the tuyere level to
the top of the layers to give the new state variables. The new positions of
each layer are calculated with their new volumes based on the geometric
profile of the blast furnace.
If the height of the top of the layers is lower than stock level at the
particular time, one or some charges are made to fill the space between
the top of the layers and the stock level.
Behavior of the blast furnace in any operation can be simulated by
iterating the calculation steps mentioned above. An example of the
calculated results for the steady state operation of a blast furnace of
1350 m 3 in inner volume is shown in Fig. 3.7.2.
oil is one of the main control parameters for the furnace heat condition,
namely the hot metal temperature (H.M.T.).
The simulated result shown in Fig. 3.7.3 has a good agreement with
the actual result in Fig. 3.7.4. It takes rather a long time to reach the new
steady state in the case of heavy oil injection. This also occurs for change
in ore/coke ratio, oxygen enrichment and blast volume rate, but the time
is smaller for blast temperature and blast moisture change as shown in
Fig. 3.7.5.
+40
+30
+20 H. M.T.
+I0
0
-0.5
0
+30
+20 T.G.T
+10
0
0
2 Reduction (+4.IKmol/min)
0
Total Reductionn-----(-5.5Krnol/min)
0
- 2 CO Reductio n (- 3.4 KmoVm in)
0
-2 O'irect Reduction (-3.5Kmol/min)
-4
0 5 10 15 20 25
Time(hr.)
Fig, 3.7.3. The simulated result of the dynamic response to the change in heavy
oil injection by 7'5 kg/H.M. ton for the blast furnace of 3000 m 3•
GLOBAL FORMULATION 275
+40
-------
Hot metal
+ 30
T
tlO
20
----
O~~~-----;~-------
-0.4
-0.2
O¥-~~----------------------
- I
- 2
- 3
....... _--
D i rec t Reduction
o 2 4 6 8 /0 /2
( Hou r)
Fig. 3.7.4. The experimental result of the dynamic response to the chanSe in
heavy oil injection by 5'0 kg/H.M. ton for the blast furnace of 1850 m .
276 BLAST FURNACE PHENOMENA AND MODELLING
+40
~30
o~-------- (+29°C)
-10 H.MT
-20 (- 2~'5°C )
-30
_ _ CO/C02
Or-~~==---~~-
-005 CO/C02
O~-===~--------- T.G.T (tI4°C)
-10 TG.T (-1°C)
o K======~(r::I_II.::i3I1(;Km;;:;;o:;[;V;;:;;min)
- 2 Total Reduction
O~==== ____,-=-;~~~
- 2 (-O.2Kmol/min)
CO Reduction
- °+--C====~r-:;-;-~~
2I . (-I. I Kmol/min)
-4
Direct Reduction Direct Reduction
o 5 10 15 20 25 () 5 10 15 20 25
o -----
-IO~.M.T.
- 20
- 30 (-330C)
Toto I Reduction
-4 ( -'52 Kmo !;min)
0
-2 (-3.1 Kmo!;min)
H2 Reduction CO Reduc-:ti~on::--~'::':';-
0
°k:===="I(r:-vi'l'~.6:1<Kmrncoor;l;;;;m:J;;-in ) -2 -----r:z-T Kmol/m in)
- 2 Direct Reduction -4 Direct Reduction
o 5 10 15 20 25 0 5 10 15 20 25
Fig. 3.7.5. The simulated results of the dynamic response of blast furnace to the
step change in (a) BT from 1250°C to 1150°C, (b) BY from 4850 Nm 3 to
4650 Nm 3, (c) BM from 10 g!Nm 3 to 20 g/Nm 3, (d) Ore/coke ratio from 4·1 to 4'0,
for the furnace of 3000 m 3 volume.
GLOBAL FORMULATION 277
It was assumed that the decrease of descent velocity at the top of the
furnace for an hour or two after the shutdown is brought about by the
scaffold formation caused by resolidification of the melting zone during
the shutdown, and that subsequent slipping is caused by remelting of
this solidified scaffold. Therefore, in the simulation, no charge is made
until this scaffold has remelted. The time required for the remelting is
given by the mathematical model itself. The result of the simulation is
shown in Fig. 3.7.6 where the blast and charge parameters were input
Actual
Calculated
J\ fl.
\:i \ I
~
O/C 3.4
25 I
I
,_.Jr.J
1.2 CO/C02
(-) 1.1
1.0
0.
slipping
12 o 12 0 12 o
Time( hr)
Fig. 3.7.6. Simulated results of blast furnace operation before and after
shutdown for the furnace of 4200 m3 .
278 BLAST FURNACE PHENOMENA AND MODELLING
a) 4
2
1550
H.MT
(OC) 15O'Jt--"-- t--c-f"'~LT9>'-- - - - - -
1450
b)
30 O/C 40
15
H.M.T
(OC) 1::Yv\.'I--~~ --+--+---,1- 7'7£---"H".M'.t - -
1450
-20 -10 20 30
c) -16hr -9hr-3IT1 ~.~~______~O~/~C~
1550 3.2
H. M. T __ ;::::::==-
( 0C) 1500+---~"'---+- +---,...7",,'7-'7-
1450 H.M.T
-10 20 30
Time(hr)
Fig. 3.7.7. Calculated results of the effects of (a) the inteIVal shutdown, (b) the
change in orelcoke ratio (O/C) before shutdown, and (c) the change in OIC after
shutdown on the recovery of H.M.T. for the blast furnace of 4200 m 3 inner
volume.
5000
25
4000
3500 20
3200
3000 0;,
15
C
(Nm' )
~n 2000
Geametric
10
rate profi Ie
1000 12aa
sao 5
0 I-----J
40 400
CO(%)
30
(%)
20
eo}%) o /
.. ~
10 /
~'" T.G.T (Oe) o. Actual
0
~ ........ = Calculated
____________________________________ ~r
I I I I I I I I
0 5 10 15 20 25 30 35 40
Time (hr.)
Fig. 3.7.8. Simulated results of the blow-in operation for the blast furnace of
3600 m 3.
GLOBAL FORMULATION 279
- - schedu led
[ _ _ actual
____~B~last temp~________~~====~
Stock level
(m)
lJ-t"'=----- - - - H . M.T.
-------
(Ton) Water sprinkled
~===Co::=(=%=):::::::::::I~
(%) IO~ \~
o C02(%) ~ ~
o 4 8 12. 16 20 24
Time (hr.)
Fig. 3.7.9. Results of blow-out operation with the decrease of stock level for the
blast furnace of l350 m 3.
280 BLAST FURNACE PHENOMENA AND MODELLING
from the actual operation. The effects of the interval of shutdown and
changes in the charge parameter (ore/coke ratio) have been studied as
shown in Fig. 3.7.7, through which the schedule of controlling ore/coke
ratio should be optimized in order to get smooth recovery of the blast
furnace after the shutdown.
(b) The blow-in ofthe blastfurnace. The initial condition of solid in the
furnace can be given from the actual results of filling of coke and
burden before the blow-in. Then the blow-in operation can be
simulated according to the schedule of the increase in blast rate and
blast temperature. One of the simulated results is shown in Fig. 3.7.8.
The adequacy of the model for the application to the planning of the
blow-in of the blast furnace was confirmed.
(c) The blow-out of the blast furnace. An example of the simulated
results is shown in Fig. 3.7.9, where a blast furnace of 1350 m 3 in inner
volume was blown out with the decrease of stock level from the top to the
upper bosh under the schedule predicted by this mathematical model.
The actual results are in good agreement with the schedule and the
predictions by the mathematical model until the top of the burden
reached a height around half the hearth diameter above tuyere level.
3.8. NOTATION
Greek letters
a apparent angle of repose (-)
aj apparent angle of repose of j-th layer (j = 1,2) (-)
ai molar fraction of i-th component in hot metal (-)
ab inclination angle of large bell (rad)
a xy , f3xy permeability in packed bed in directions
x and y (I/L, Mt/L4)
a o, f30 coefficients of permeability at layer 0 (l/L, Mt/L4)
f3a effective area for reaction per unit surface
area of coke (-)
f3b inclination angle of feeding hopper (rad)
f3c, f3H mass fractions of C and H in injected oil (-)
Yc mass fraction of C in coke (-)
8 representative length (= d/6Ej) (L)
Lli vertical depth of i-th block (L)
Ll,j, I vertical depth of j-th layer in i-th block (L)
C'CI void fraction in bed and c at tuyere level (-)
Cl ratio of liquid volume to void volume in
packed bed (-)
GLOBAL FORMULATION 289
SUbscripts
b burden
be belly
c coke
g gas
gs between gas and solid
gl between gas and liquid
in inflow
i-th component
J j = 1, 2 (1, coke layer; 2, ore layer)
k k-th reaction
I liquid
M cohesive zone (1300-1400°C)
o ore
out outflow
R raceway
r component for r-direction
,rz partial differentiation with respect to rand z
S cohesive zone (1200-1300°C)
s solid
sl between solid and liquid
wi inside wall
wo outside wall
we outlet of cooling water
x component for x-direction
,x partial differentiation with respect to x
y component for y-direction
z component for z-direction
o at top of bed or initial condition
I at tuyere level
~ II vertical and parallel to layer respectively
GLOBAL FORMULATION 291
REFERENCES
65. S. Fujita, Kagaku Sochi Benran (1965), 259, Kagaku gijutsu Sha.
66. M. Sugata, T. Sugiyama and S. Kondo, Tetsu-to-Hagane. 58 (1972),
1363.
67. A M. Samarin, A W. Poliakov and L. A Shvartsman, Izv. Akad Nauk
SSSR, 12 (1949), 1639.
68. 1. A Curie, Brit. J. Appl. Phys., 11 (1960),318.
69. C. Slonin, Z. Elektrochem, 36 (1930), 439.
70. G. F. Hutting and H. Kappel, Kolloid-Z.. 91 (1940), 117.
71. H. T. S. Britton, S. J. Gregg and G. W. Winsor, Trans. Faraday Soc.. 48
(1952),63.
72. 1. H. Perry, C. H. Chilton and S. D. Kirkpatrick, Chemical Engineers'
Handbook, McGraw-Hill (1963).
73. A W. D. Hills, Chem. Eng. Sci., 23 (1968), 279.
74. W. M. McKewan, Trans. AIME, 218 (1960), 2.
75. W. M. McKewan, Trans. AIME, 221 (1961), 141.
76. T. Otake, S. Tone and S. Oda, Kagaku Kogaku, 31, (1967), 71.
77. Y. Nakamura, E. Tsunetomi and S. Kondo, preprints of 55th TIM
meetings, Toyama, Japan (1964), p. 65.
78. M. Kunugi, H. Jinno and H. Torii,J. Chem. Soc. Japan, Ind Chem. Sect., 56
(1953), 46.
79. W. Graven and F. 1. Long, J. Amer. Chem. Soc., 76 (1954), 2602.
80. J. M. Moe, Chem. Eng. Progr., 58(3) (1962), 33.
81. J. Yagi and I. Muchi, Trans. ISIJ, 10 (1970), 181.
82. C. Yoshii and T. Tanimura, Tetsu-to-Hagane, 51 (1965), 1823.
83. Iron and Steel Institute of Japan, Koro Seisenho-no-Riron (Domennyi
protsess by AD. Gotlib (1958), translated by M. Tate into Japanese) Iron
and Steel Institute of Japan, Tokyo (1966), p. 333.
84. Ibid., p. 331.
85. J. Perry, C. H. Chilton and S. D. Kirkpatrick, Chemical Engineers'
Handbook, McGraw-Hill (1963).
86. W. E. Ranz, Chem. Eng. Progr., 48 (1952), 247.
87. 1. C. Agarwal and H. R. Pratt, Blast Fum. Steel PL., 55 (1967), 405.
88. T. Yamada, T. Yonezawa, T. Nagai and M. Nozaki, technical report, Fuji
Iron & Steel Co., 15 (1966), 99.
89. T. Hasegawa, H. Nemoto, E. Sakamoto and K Kuroda, Tetsu-to-Hagane,
51 (1965),628.
90. T. Kitagawa, H. Ota and K Kimura, Tetsu-to-Hagane, 53 (1967), S205.
91. N. Meysson, A Maaref and A Rist, Rev. Metall., 62 (1965), 1161.
92. P. L. Woolf, J. Metals, 18 (1966), 243.
93. 1. A Peart and F. J. Pearce,J. Metals, 17 (1965), 1396.
94. M. M. Fine, P. L. Woolf and N. Berstein, USBM Rep. No. 6523 (1964).
95. K Wakabayashi, M. Fujiura, T. Mori and N. Inoue, Tetsu-to-Hagane, 55
(1969),867.
96. T. Yatsuzuka, K Nakayama, K Ohmori, Y. Hara and M. Iguchi, Tetsu-to-
Hagane, 58 (1972), 624.
97. T. Kobayashi, F. Nakatani, K Okabe and T. Miyashita, Tetsu-to-Hagane,
55 (1970), 881.
294 BLAST FURNACE PHENOMENA AND MODELLING
This chapter deals with the flow phenomena in the blast furnace. The
blast furnace is a counter-current reactor of rising gas and descending
liquid and solid. Since energy for reduction and heating of iron ore to
produce pig iron is supplied by the rising gas, the flows of gas and solid
in the furnace are crucial to furnace performance in both fuel rate and
productivity. While all aspects of the flows of solid and liquid in the
furnace are discussed, only a part of the interesting area of gas flow is
mentioned in the present chapter. One of the major fields of interest,
raceway phenomena, is discussed in Chapter 6. The following subjects
will be discussed:
297
298 BLAST FURNACE PHENOMENA AND MODELLING
Of the three phases - gas, liquid and solid - present in the furnace,
the flow of the gas has been most extensively investigated. Owing to
FLOW OF GAS, LIQUID AND SOLID 299
these investigations and the relatively simple kinetics of the flow in the
empirical formulation, it is now not very difficult numerically to
simulate gas flow in a packed bed of known distributions of particle
diameter, porosity and temperature, On the other hand, present
knowledge about the flows of solid and liquid in the furnace is not as
well developed. Therefore the aim of this chapter is not to present a
comprehensive account of flow in the furnace, but to give an account of
the latest knowledge. It is expected that this will give the reader a clearer
insight into the physical phenomena in the furnace. However, it must be
stressed that descriptions of the phenomena have been given quantita-
tively wherever possible.
l'"
\
Hyd(oulic unll
Furnoce ,hell
J
i/
101 Bell lOp wllh movable armor 16
I
I
I
lorse bell ' ¥.........- J... O
'"
\
\
\
\
\
y
burden surface, the throat wall or the movable armor to form a burden
profile.
These four stages, as described above, are involved in the trajectory of
burden materials at the furnace throat.
(b) Formulation o/the/alling trajectory. We imagine that the large bell
lowers enough to allow the burden materials to discharge. The total
energy T of a unit volume of granular bed at level h 0 in the large bell
hopper is described as
(4.1.1)
where Pb denotes the bulk density of the bed, Vb the descending speed of
the particles,gthe acceleration due to gravity, andh o the distance from a
point made by the hopper wall and the large bell surface.
In the vicinity of the hopper exit, the area where the particles flow
downwards is approximately expressed as follows:
S = 21TR H(D H - kdp ) (DH">kdp) (4.1.2)
where RH denotes the radius of the annular hopper exit, DH the
horizontal clearance at the level h, and d p the mean size of the burden. k
is a dimensionless parameter to be empirically determined and is equal
to about 4, as mentioned previously.
The descending velocity Vb is expressed in terms of ho with the aid of
the correlation DH = he/tan 0b:
Vb = W/PbS = W/Pb21TRH(ho/tan Ob - kdp ) (h o "> kdp tan (}b) (4.1.3)
where W denotes the mass flow rate.
According to Brown's theory,2 the total energy T is dissipated by the
burden descent in the hopper attaining a minimum at the level where
the dynamic arch is formed, where h 0 is approximately equal to the large
bell opening ha:
(dT/dh)ho=ha = 0 (4.1.4)
Substituting eqn (4.1.3) into eqn (4.1.1) and defining the descending
velocity u D (= Vb) at the level of the dynamic arch h a' we may rewrite eqn
(4.1.4):
(4.1.5)
The velocity of particles u E striking the large bell surface after the free
fall from the dynamic arch is written as
(4.1.6)
FLOW OF GAS, LIQUID AND SOLID 303
where it is assumed that the average fall distance is h a!2. Assuming the
nonelastic collision of particles to the large bell surface, we obtain the
initial velocity U Esin (Jb of particles moving along this surface and the
velocity at the edge of the large bell U o:
(4.1.7)
in which 10 denotes the distance shown in Fig. 4.1.2 and /1 the friction
factor of the large bell. The free fall trajectory of particles leaving the
large bell edge is described as
(4.1.8)
If we prepare the data on large bell dimensions 10 and (Jb, friction
factor /1, mean size of particles d P' and large bell opening h a' the falling
trajectory of the burden material leaving the large bell may be
calculated with the aid of eqns (4.1.5)-(4.1.8).
The calculated results for coke and sinter are shown in Fig. 4.1.3. It
r
will be seen that, the lower the bell descends, the closer to the wall the
- 2.2 ~ -2.2 ~
r
0.1 -
-2.0 0.2 5
200mm -2.0 2 mm 0.2 5
0.3 :? 0.3 :?
-18 500mm OA·~ - 1.8 00
500 OAO'
- - 050- ~ O.5~
-1.6 700mm 0.6 - 1.6 700mm 0.6 0
- - 0.7 -- 0.7
-lA -lA
-1.2 -1.2
-1.0 - 1.0
E -0.8 -0.8
]0 E
~ -0.6 L -0.6 0
E
00
0
I "- OA <{
4' -OA 9
<{
:;: -0.2 :;:
·-0.2
SlOm SlOm
0 0
0.2 0.2
OA 0.4
0.6 0.6
0.8 0.8
1.0 1.0
1.0 0.8 0.6 0.4 0.2 0
Distance from wall (m) Distance from wall Iml
laJ Coke Ibl Sinter
Fig. 4.1.3. Calculated trajectories of coke and sinter from a large bell.
304 BLAST FURNACE PHENOMENA AND MODELLING
burden materials fall. In this case the movable armor comes to affect the
falling trajectory at a position at least 600 mm inwards from the
wall.
(c) Burden profiles obtained by use of movable armor. Figure 4.1.4 shows
the coke layer profiles obtained for three movable armor positions:
600 mm, 800 mm and 1000 mm inwards from the furnace wall. 3 In the
600 mm case, the burden profile is similar to that obtained without
movable armor. The 800 mm position gives a typical burden profile
obtained by use of movable armor; the coke layer is thinnest at the wall,
thickest about 1· 3 m inwards from the wall, and gradually decreases in
thickness towards the center, although that is affected by the base
profile. In the 1000 mm case, such a tendency is extremely pronounced.
1000
cc.
TABLE 4.1.1
Physical Properties of Blast Furnace Burden
"Calculation conditions: top gas temperature 120°C; top gas pressure 2 atm.
bF = 1'75(1 - e)/ct> s d p e 3.
1010 .
c;,
C>
~ 30 ~::....z!---+--+--+-l f--I=~~--1
(;
'0
io 25
.,u
j 2° I~ilti!E§11
0.06 0 10 0 14 0 18 0 12 0 14 0 16 0 18
Chorge omount H R I t
Fig.4.1.5. Influence of charge amount and pellet ratio on surface angle of ore.
306 BLAST FURNACE PHENOMENA AND MODELLING
34
101 C j
'"
<D
:'2
<D (
0 0 ~
8 32 AO-o~
'0
~
~~-
.2!
'"o
c
00 0 '1
0 •
:'; 30
Charging weight of coke It/chi
~
</) x 103 _/130 .15.5/ A 18.0
V 20.7 t; 26.0 0 310 0 36.0
28
15 20 25 30
Surface angle of ore below coke Idegl
36
• Ibl C,jC"j
~
en
<D
2:'
~ 34
""" ~
u
•----
.2!
'"a
c
•
32
:'; .......
.g
~
</)
30
10 15 20 25
Charge amount of C" It I
Fig.4.1.6. Influence of (a) surface angle of ore below coke and (b) charge
amount of coke, on surface angle of coke.
volume during a start-up period and confirmed that the surface profiles
were different, the profile with high blast volume having a smaller slope
than that with low blast volume. Conducting experiments with a
reduced scale slice model, Sugiyama et al. 6 demonstrated that the
surface angle decreased with increase in the gas velocity, reaching zero
at the minimum fluidization velocity.
According to Nishio and Ariyama/ we begin by considering an
elementABDC given by a pair of parallel faces one of which lies along
burden slope at an angle f3 to the horizontal plane, as shown in
Fig. 4.1.7, with gas flow perpendicular to the burden surface CD. The
gravitational force of the burden and the drag force caused by the gas
flow act on this element. The shear stress acting on the face AB is
r = Pb(g!!.L) sin f3 (4.1.9)
FLOW OF GAS, LIQUID AND SOLID 307
y
stream line
40r---~---'----'---~----~---
Q)
u
~
~ 10~--~--~--~4-~~----+---~
5 10 15 20 25 30
Pu' (kg/m's')
(c) Decrease in suiface angle with burden descent. The surface angle of a
charge affects the radial variation in the layer thickness of the next
charge, by decreasing during the interval between charges as shown in
FLOW OF GAS, LIQUID AND SOLID 309
center wall
Fig. 4.1.9. Decrease in surface angle with burden descent.
Fig. 4.1.1.0. C~ange of coke la~er surface and formation of mixed la~er when
smter is charged (full Size model of Kimitzu No.3 furnace). I
310 BLAST FURNACE PHENOMENA AND MODELLING
the furnace center to form a mixed layer there. This phenomenon is one
of the important factors which promote central gas flow.
(b) Coke dam. When dissecting an experimental blast furnace, Ando
et alY found that the distribution of burden charged prior to blow-out
was different from that charged after blow-out; the former distribution
had a coke pillar at the center, whereas the latter had no coke pillar and
ore was present even at the center. According to the dissection of the
Tsurumi No.1 furnace where ore of70% pellet ratio was charged, a coke
pillar was observed at the center with normal blast volume, whereas the
coke pillar diminished with reduced blast volume just before blow-out. 13
These results suggest that coke is fluidized at the center. However,
according to the data listed in Table 4.1.1, the ore would fluidize, instead
of the coke, because the minimum fluidization velocity of ore is smaller
than that of coke.
This discrepancy was eliminated as follows. 7 The data listed in Table
4.1.1 show that the apparent friction factors of sinter and pellets are
much larger than that for coke. The difference in such a factor affecting
the permeability plays an important role. As shown in Fig. 4.1.11, the ore
leaving the large bell strikes the throat wall; it then moves from the
periphery toward the center on the coke layer while the gas, avoiding the
less permeable ore layer, is deflected toward the center and fluidizes the
coke there to form a coke dam which blocks ore movement.
This mechanism was confirmed by means of model experiments. 7
The burden distribution formed in the gas flow can be visualized with
the aid of Photo 4.1.1,14 where the inclination angle of each layer
decreases with increase in the gas velocity indicated at the throat. The
coke dam is formed at the center when the gas velocity exceeds a critical
value and this noticeably reduces the ore/coke ratio at the center, as
shown in Fig. 4.1.12.14
Both the mixed layer and the coke dam described above can occur at
the same time in a blast furnace to affect the gas distribution.
l"
o
Cetlter
Radlol pOSIhon
101
Ibl
Fig. 4.1.13. Burden distribution (a) without and (b) with movable armor
control.
3.5
II 3.5
U 3.0
S; 3.0
'~ u
E 2.5
\ i
Q)
25
\
.-f'
u 2.0
~
1:
0 1.5
\ ~
u
~
2.0
\ ""'"'
I"- ~ r-.---' \
Q)
~ 1.5
\
())
\..
"
o
1.0 ())
2
~
\ " 1.0
f-
0.5 l'
f- 0.5
00
\
Sl 1.0 2.0 3.0 4.0 5.0 o
Iml
0
p u 2 =2.2
0.7 0 ~91 0 Sl o 1.0 20 3.0 40 5.0
0
04 0506 Iml P u 2 = 22
02°3
2
2
3
3
4
4
5
5
6
6
7
8
8
9
9
10
B B GOO 700 800 B
10
CC lOC>l cc POl cc lOOl
2·0 2·0 2<l
101 Ibl
Fig.4.1.14. Streamlines and isobars (a) without and (b) with movable armor
control.
l:::
1.0
3Bf
with armor
,
f- "8
FUkUYO~4
X
4 movable
..... 1\"
FUku~~A
4Bf ............
1 BF FUkUY~;;;-- ~O oemoe FukuyamCl
2Bf 5Bf
Q; 0.9
Fukuvama- ............
3BF IWlthout
.........
0 1974
armor)
.......
-
" 1975
X 1976
0.8
2000 3000 4000 5000
Inner volume lm 3 )
--
expressed in vector form as
rna= F g - ---
rn[w X (w X r ) I - ---
2rn(w X v ) - F r (4.1.17)
-
where rn is the weight of the point mass (M),-; the acceleration (Lt- 2),Fg
the gravitational force (MLt- 2), w the angular velocity of the chute (e l ),
-;- the radius (L), -: the velocity of the point mass (Lt- l ), and Fr
frictional force (MLt- 2).
On the basis of the coordinate system shown in Fig. 4.1.16, eqn
(4.1.17) has been solved numerically using the Runge-Kutta-Gill
method for the longitudinal (L), the tangential (T) and the normal (N)
directions to the chute inner surface. An example of calculated results is
shown in Fig. 4.1.17 for the case of the chute used at Chiba No.2 blast
furnace (Leh = 3 m, Heh = 1·02 m, reh = 0·57 m) under the following
conditions: chute rotating speed 8 r.p.m., tilting angle 50 initial 0
,
I. 1.0 1.0
~ 3 ~ 30
Ul en
:g 2 ~ 20
..J a) ~~10
> 1
L direction b)
0.2
T direction
o F-~~~-~--1 8~ __
--- ~ 6
'0
~ I.
Fee
:§: 2
--F~o------ z
III 0
'-._._.-I,__ -I. Fg -2
c) N direction
-6 -I. '--~~~-:--~-'
0.43 0.86 t29 1.72 2.11. 0 0.1.3 0.86 t29 1.72 2.11. 0 0.43 0.86 1.29 1.72 2.14
leh (m) L~, leh (m) Lt, leh (m) L~,
Fig. 4.1.17. An example of changes of variables on the chute.
FLOW OF GAS, LIQUID AND SOLID 317
a large effect on the motion of the point mass. On the other hand, the
Coriolis force component in the T direction is greater than that of the
gravitational force in the major part of the chute, although its maximum
value in the L direction is at most equivalent to 20% of the gravitational
force. In the range of small eM, the T component of the Coriolis force
mainly acts upon the point mass to lift it up along the inner surface of
the chute. With an increase in eM, the N component gets larger and
becomes comparable to that of the gravitational force at a eM value of
50 0 • In the range oflargere M, the gravitational and Coriolis forces press
the point mass on to the chute surface. If the Coriolis force is ignored,
the velocity component in the L direction is calculated to be somewhat
larger than its correct value because of the reduction of the frictional
force, and the lack of the associated decelerating effect in this direction.
The calculated values of eM at the chute end have been compared
with observations from photographs. Good agreement was found, as
shown in Fig. 4.1.18, and this proves that even such a simple
formulation gives correct analytical results for the complicated flow
characteristics of granular material.
50
40 =0.4,...":> .!. -- +
-
)J
. h '"
).J =0.55
en
•
-
QI
30
"0 \.C- .
::E
<:l>
CD 20
!7
10 • obs .
0
30 40 50
Tilting angle, 90-4> (degJ
Fig. 4.1.18. Comparison of calculated and observed values of OM'
following full-scale test. About ten containers, cans or bags, were placed
radially in a row at different levels in order to receive the falling
materials. The radial distribution of weight fraction and cumulative
weight fraction in the stream were obtained at each level as shown in
Fig. 4.1.19. A trajectory is defined as a curve passing through the points
where the cumulative weight fraction reaches the same value, as shown
in Fig. 4.1.20. It is noteworthy that the stream is quite wide and the
trajectory of main flow, defined as that for F = O' 5, is a little above the
center line of the stream. This is one of the characteristics and is due to a
wide velocity distribution within the stream during burden motion on
the chute. Another characteristic is that an extreme size segregation
exists in the stream, as shown in Fig. 4.1.21. This is attributed to the
1·0
0-8
~
~
~ o·
4/LI..
> .•
:;:c:
~.2 0-4
~v
:l l!
u ....
0·2
0
1·0
0·8
c
.2
u
.='" 0·6
1·09 0-67
L:
.~ O.
4/
~
percolation of small particles into the spaces between large ones which
happens as the particles flow on the chute.
The falling point of the coke main flow is at a constant position
corresponding to a dimensionless radius ofO' 87 at high tilting angles as
shown in Fig. 4.l.22(a). The falling point for sinter moves towards the
wall with an increase in tilting angle and is always located nearer to the
wall than that of coke. The main trajectories of both materials are in
agreement with one another at tilting angles below 43 0 • The width of the
stream decreases with decrease in tilting angle.
The burden flow becomes wider with increase in volume flow rate, as
shown in Fig. 4.1.22(b). The trajectory of the upper boundary corres-
ponding to F = 0 moves towards the wall, but those of the main flow
and lower boundary only change slightly. In the case without ribs on the
Sinter
NCh =3
Q=O.53(m3/s)
Lch = 4 (m)
/// .
/ /!J :
/ //~'!//
/ . . /l
///;// !
/I///!
/ // III ;!
SL
Om Q/ I . /'
1/.'/ I / . I i <II
u
/ //. /1I :! c
!!!
I
I /. • .!Q
/ I / I f "0
, / . / I :
2m 1.1 i I ! :::
I !
~
/f1k} . c
.2
cs/!? a'":- i
'
VI
c
<II
E
Cl
."
\
E 10
g
.
N
'iii
c
~ •
.~
a;
E
£
5
\•
\
~
h/R=1.64
o L-__ ~ ____ ~ __ ~ __ ~
al
0
1
I 50 2
3
i
•5
6
- 0' 40 7
g>z
:!? c 8
~g
O"J .':;;' 9
c 0 30
0 Q.
"'''
.-c -"
':::L
\0
>=u 20
0.25 SinTer
- - - Coke
bl
v~ o 025 075
0.6
~
C
oJ 04
~
0.05 / 0.5 0 95
OL-__- L____L -_ _ ~ ____ ~ __ ~~
12 10 08 0.6 04 02
D'mensionless rad,us, r R I -I
Fig.4.1.22. Falling point of mass flow on the burden surface; effect of (a) chute
position and (b) volume flow rate.
FLOW OF GAS, LIQUID AND SOLID 321
_ Upper layer
--<)- -Middle layer
12 - ....-. lower layer
---A-..Mixed layer
El0
E
G.I
N 8
I,/)
c:::
I'll
G.I
:;E 6 • ......
;..,.,.,.,,------
4 -- __ .... Bag sampll'
5 432 o
Radius (m)
where 1is the distance in the flow direction (L),x n the weight fraction of
n-th size (-), an the size segregation constant (L -1), and fis a suffix for
the feed materials. By substituting x~ at 1 = 0 for x,; and rewriting for
only the n-th size, the following equation is obtained:
(4.1.19)
Values of an can be calculated from the radial distribution of size
analysis. Data for samples taken at the time of filling as shown in
Fig. 4.1.23 (bag sample) are used to calculate an values; they are 0·25
for < 5 mm, 0·02 for 7'5-9'5 mm and -0'23 for 13-5-18'5 mm. The
absolute value of an has a minimum at the harmonic mean size and
becomes larger with size deviations from this mean value, as shown in
Fig. 4.1.24. However, it is undesirable that n values correspond with only
one group of charging conditions; therefore eqn (4.1.20) below has been
derived by substituting the ratio of cumulative weight fraction under the
n-th size to that of the remainder, Xn/(l - Xn), instead of Xn in eqn
(4.1.19). Then, all an values converge to the same value regardless of
particles size as shown in Fig. 4.1.25.
log (Xn/l - Xn) = log (X~/l - X~ - a1 (4.1.20)
0.3 r--------------,
0.2
0.1
c:
1:1 -0.1
-0.2
-0.3
-0.4 1--_-'--_-'-_---'-_----''-----'
o 10 20 30 40 50
Particle size (mm)
Fig. 4.1.24. Relationship between particle size and size segregation constant.
FLOW OF GAS, LIQUID AND SOLID 323
I:
1 :
"0
~
~~;~
~::
I/~~
~ t-~:..
. .. _. :smm
• M 4BF --:--
- 1
5mm
5 4 3 2 o
RadIUs Iml
A e
Co~('
//"-------
','-------- ....-... ~-
o
"0
~
0 o
e
C e
0
~
10
o 5 0 5 0
c we We W
.•
A S,at1 ng-lUp OpetOI or
• Cer'ef'-~~ ng 0,*01'0"
54 o Modetope operat,on
• low 'uel fole O~rarlotl
52
~50
4.:; 48
'"
- 46 100110 C1
o .93J',1u C1
44 11.635
- 2 o 2 4 0 44 46 48 50 52 54
-,,0 e l l I~col"" 1%1
(1) The layered arrangement of ore and coke is maintained not only
in the shaft but also the melt-down level of ore.
(2) The layer thickness decreases with burden descent.
(3) The angle of layer inclination decreases with burden descent.
It is very difficult directly to deduce the burden descent mechanism
from the data of dissected blast furnaces, because they are influenced by
a number of disturbances. However, model experiments offer basic
information on the burden mechanism, and data both from dissected
blast furnaces and from model experiments may be used to investigate
the flow of charged materials in the upper shaft.
lfI) W
. ~
II'I/f ll
/,-~
~~ . I-- - ~"'"
bed move along the lines radiating from the apex of a cone subtended by
the tapered walls. According to this model the particles possess a
uniform component value of descending velocity, as indicated in
Fig. 4.2.2. 32
o~
-.\1\\\\\\
11\\\\\
11\\\\\
11\\\\\
1\\\\\\
1\ \\\\\
\\ \
11\\\\\
11\\\\\
1\\\,\\
1\\\\\\
lr= II \ " \ \ \
\ \ · \ \
00/ 2~
'1
\ \ \ \ \
\ \ \ \ \ \
,
~~I~I_\~\~\~\~\~S~.~L~2~m~__~r
Lo I \ \ \
,
\ \. \
I = {(l/8)(DJtan OsJ 3
+ 3[Vt - (IT/4)D5(La - I]) ]/(IT tan2Osh) }l13 - Da/(2 tan Osh) + La
for I] <La and ~ > (IT/4)DMLa -I]) (4.2.2)
I = [Da/(2 tan Osh) - La + 1])3 + 3 V/(lT tan2 Osh) p/3
- Da/(2 tan 0sh) + La for I] > La (4.2.3)
(2) Value of r
r = r] for I] < La (4.2.4)
r = r][1 + DJ(2 tan Osh) - L a]/[DJ(2 tan Osh)]
for I > La and I] <La (4.2.5)
r = + DJ(2 tan Osh) - Lo]/[/] + DJ(2 tan OsJ - La]
rdl
for I > Lo and I] > Lo (4.2.6)
Equations (4.2.1)-(4.2.6) give the location change of any particle in the
burden with the descent of one charge of volume ~.
Descent rate
of an inclined layer has a larger descent rate than the central portion.
Therefore the angle of inclination of the layer decreases as the burden
descends.
Based on these assumptions, the reduction in the angle of the layer
inclination has been calculated using eqns (4.2.1 )-(4.2.6), and compared
with data from an operating blast furnace as well as a dissected blast
furnace.
In Fig. 4.2.5 calculated angles of inclination are shown for the descent
of five charges where the five positions on each layer contour are
connected by straight lines to give four segments. We see that both the
inclination angle of each segment and the layer thickness reduce with
burden descent. The decrease in these inclination angles is more
obviously illustrated in Fig.4.2.6(a). In Fig.4.2.6(b), the inclination
angle of each segment is plotted as a function of the charge numbers
indicated in Fig. 4.2.5. This figure suggests the following characteristics
of burden descent:
(1) The rate of change of inclination angle decreases with burden
descent.
(2) The larger the inclination angle, the larger the rate of decrease.
MA Setting, 800mm
-4.7'
9
ChNo6
o 1 2 3 4 5
Distance from center
2 r---'---~----~------~~--,-,
]
g
.
~ A
o Ol-·-=+----+----+---! - ~ +--+--1
o 6
o 2 3 5 6
101 Dlstonce rrom center 1m'
40
"---.., '-
_30
--.
.,0>
.,
:9 ::::::::~ ~ r-- r- I
~ ~
]>20 _.Segmenl
o
c
• I
.2 a II
.~ 10 '-A
..
III
v IV
.E
-10
o 2 3 4 5 6 7
Ibl Charge No. I-I
Fig.4.2.6. Change in (a) layer profile and (b) inclination angle, with burden
descent.
o M.A 0 mm
.,
0. • M.A 700mm
~ 0
g>" ~-"
. -2
c - I
~ ~~
-
u
.2 ~~-
~
<; - 3
.,
C -4
"
u
c" o 5 10
TIme cfler charging (mln(
attributed to the lining wear which arose for levels greater than 10m (as
shown in Fig. 4.2.9), the basic idea proposed here to express burden
descent is consistent.
These results lead to the conclusion that the burden descends with a
somewhat uniform speed in the shaft and that the decrease in the layer
inclination is mainly caused by the tapered shaft wall.
012340 10 40
distance from center layer angle
1m J
Fig.4.2.9. Comparison between calculated coke layer angle and measured
values in shaft (Tsurumi No.1 furnace).
shown in Fig. 4.2.11. The burden proftles obtained from the dissection
of the Amagasaki No.1 furnace 24 and the Chiba No.1 furnace 28 suggest
that this phenomena can arise in the blast furnace.
2 J
3 1
4 J
5
]
I
6
7
,/ ~l~
l\-
ci
Z 8 i Worn pori
'"'<;"
-"
9 ~
U j
10
II J
I
r
12
13
14 I.
15
o
1 30
10 20
Incl inollon ongle Idegi
esh: 83'
o
r
~ Stream I.ne
T,•• ,,".
~ . I(
Fig.4.3.1. Stream lines and time lines measured with tracers.
FLOW OF GAS, LIQUID AND SOLID 337
near the wall the particle velocity is very low on account of friction
between particle and wall. The flow pattern of particles in the tuyere
region results in funnel flow.
1-----240 ----I
i
40
Hopper
I
Pressure Top
Camera
I
o
o
Sampling Box
Wall Center
,,
, I
I
20 I I I I I
I I I I
I
,
I I
I I I •
//',
·
I I I
I
15
"I I I
I I
I /"
/' , ....--zone
• B
I," )/j
0 I/Il"
I
Z
0 I I
I I f
C;;;
0 , ~I
10
I II~I/ I
...--zone A
I /~~/ I
'I,'
I , ,
3 5 7
GRID NO, I-I
Fig. 4.3.3. Vectors of particle velocity in steady state. 37
Wall Center
,-----------,
h-r-r-.--~.-----.-ll = 0 sec
11-+----+-----t--"1 100
200
300
I 400
500
o 600
z BOUNDARY of
g DEAD ZONE
('5 IW = 5,0 g!secl
3 5
GRID NO, I-I
Fig. 4.3.4. Time lines and stream lines in the raceway region. 37
FLOW OF GAS, LIQUID AND SOLID 339
High - low
Wall Center Wall Center Wall Center
3. 0 ,----------,
Key Vg (I mini
6. 70
2.0 0 200
0 300
W=5 g, sec
u 1.5
~
E
.§
1.0
0.5 _..ll----- n
-"i-~;.-
~
5 3 5 3 5
GRID NO. I-I GRID NO.1-I GRID NO.1-I
Fig. 4.3.5. Relation between gas flow rate and descent velocity distribution for
various heights.3?
High - - ---Low
Wall Center Wall Center Wall Center
3.0,-----------, ,----------,
I
I
K \ Vertical
Vertical GRID NO. 20 Vertical GRID NO. 15 /; \ GRID NO. 10
2.5
Key W (g/secJ
1\ \
2.0
o
V TO
I \\
o 15 f \\
\\
. I
\ <l\
.,
~ .....\ \\
\ \\
\ .\
\ \
GRID NO.1-I GRID NO. I-I GRID NO. I-I
vertical Grid No. 20, descent velocity does not vary significantly across
the radius with increase in discharge rate.
At the lower part, shown in vertical Grid No. 15 or No. 10, the descent
velocity varies in the radial direction and increases markedly near the
tuyere.
4.3.1. Formation of Mixed Zone in the Peripberal Region Near the Wall
p
1 s
c i c
p s
v i
!
"
1\ c c
\
v p
! S
I
'y'l.
C c
1
~
J P s
'Fc+ ~
: t·····j "\
Fig. 4.3.7. Burden descent and mixed zone observed by dissection. 39
easily formed above the projection, and also the burden is mixed under
the projection. Scaffolds have a larger influence on the obstruction of
burden descent than wall erosion.
-_._---
.. ...
,..,.....,............-
.......-. ~ ..........
",....., ......,. .. ·t\. ~ ..
(a) (b)
(d)
Fig. 4.3.8. Effect of shaft deformation on material flow during stack descent
(Ws = 5 gis, Vg = 200 Vmin). (a) T = 0 s; (b) normal; (c) scaffolding, T = 140 s;
(d) wall collapse.
lad'segment model
1 Vessel
2 Bell
3 Table feeder
4 Motor
5 Roots blower
6 Orifice
7 Manometer
8 Thermometer
9 Baffle plate
supply of coke from the front or side of the raceway was not observed,
This phenomenon is decided solely by a mechanical balance between
gas flow and solid particles around the raceway.
E 1
~ 0.8 o Pellet Op=2~5mm .~ f-
o C Coke Op=5~10mm
::E 0.6 f-
~
E
~~4~ _ :A-
0.' o S-F'=15mm " .....• f-
Q2 0 ~/I
...J
<l
a::0.1 o
<l0.0 8
1//
6-/.-Y-
.I
0.0
0.04 - It.
0.0 2
0.01,
I
2 4 6 810
QG ( NmJ/min)
-="E 2.0
g
.:i:'
dead zone
i
Cl
1.0
i--
.
boundory
of the rocewoy
0~
0 L-~1~.0~--2~.0~--~
3 .~0~
Distance from furnace wall Iml
IBI 10 IOJ
c w
Plote
,
v,
. e
\1
• 60·
o 4Y
5 " 30·
•s
_ 10
e
\0\
~ 15 if
J: 20 ~
25 \
o 5 10 15
l leml
standing of this profile has great importance for control of the cohesive
zone.
zone where coke descends radially between the cohesive zone and the
dead man. In these regions, the arrangement of coke particles changes,
and the permeability characteristics are different from those of the plug
flow region.46 The permeability of the moving coke zone with funnel
flow has been studied by a counter-current moving bed (see Fig. 4.3.14).
This model was an 800 mm long counter-current moving bed
(100 mm 0), with an inner wall covered by coke particles of 5-8 mm. In
order to achieve satisfactory pressure drops ranges, the model was
packed with coke particles of average diameter 4'5, 5·33 and 7·4 mm.
The bed diameter and particle size were determined by a slit model so
that the coke exhibited funnel flow in the measured range of pressure
drop. During descent of the burden with air blown from the bottom of
the bed, the blowing rate, pressure drop and descent rate at the bed
1 Roots blower
9 2 Valve
3 Orifice
4 Manometer
5 Thermometer
6 Motor
7 Table feeder
8 Moving bed
9 Scale
surface were measured at the time when the blowing rate and pressure
loss reached a steady state.
Figure 4.3.15 shows comparisons of pressure drop just after packing
(fixed bed) with that of steady descent (moving bed). The pressure drop
of the moving bed is approximately half that of the fixed bed. Moreover,
the descent rate appears to have no influence, and the coke bed
descends with a constant void fraction. The void fraction e of the funnel
flow region can be estimated by Ergun's equation, taking the shape
factor into account:
l:i.P
(4.3.1 )
l:i.L
~ 0.6 o , - - - - - - . - - - , - - , . . . , . , . - - , - - - - - - - . - , . . . , - - , - - - - r - ; - - , - - - - ,
E dp :45mm
~ 0·40 i2Ss:Q65
9..
I
Vs (em/mln)
o 3.2 - 4.5
E 0.20 ! 1. 3-12.1
~ '13.3-22.9
0.10t---+_-
0.08
...J 0.06
<J
- 0.04
Cl...
<J
0.02
0.01
000 ~~O---;:';;-~~;';;-;~;;--~20;;-----:40:'::--:!:60::-80::'::-:-:10::::0--L-==-==----!;40::---;60:';::-;:80':cl:±OO;;----'
Fig. 4.3.15. Comparison of pressure drop between fixed and moving beds?8. 39
066 Dplmml
0 4.SO
0.64 ~_
Ivr _ O • ing b ea )( 533
•..
-
0.62 6.SO
740
~~
- 0.60
I
0,54 ~~'~ed b
A -
i .....
. ed
0.52
4 ..........
O,SO ....... r--
0.48
055 0.60 065 0]0 0.75 0.80
¢Is I-I
TABLE 4.3.1
Replacement Period of Dead Coke Zone Measured with Radioactive Coke48
Test Changing position of radioactive coke Period before detection
iron attack, the volume of pig iron which drops down through the
peripheral zone is large, and is relatively small in the middle or
central zone.
(2) Coke in the central or middle zone is only consumed in 15-19
days, i.e. the replacement of dead coke is very slow.
Furthermore, the dead coke piled up on the coke bed in the hearth
moves up and down according to the tapping cycle. In this case, the peak
of the dead coke zone is unstable and is renewed by the next cycle of
descending coke as much as coke movement towards a tuyere, and the
peak becomes roundish. This has been verified by a simulation
experiment49 using polystyrene balls and glycerine solution.
In an operation with a V-shaped cohesive zone, as was observed in
dissections of the Kawasaki No.3 furnace and the Amagasa"ki No. 1
furnace,43.so coke in the central part (central coke) must descend. In such
a case, coke particles probably float up from the hearth toward the
raceway. This phenomenon has been experimentally observed and is
shown in Photo 4.3.3. 51 In a two-way dimensional model of the hearth,
which was divided into central and peripheral regions, resin balls
(5 mm, Pb = 0'8) were packed and mercury was added to a given level.
Subsequently, the balls were discharged from the raceway zone, and
balls were supplied in the central region. When the mercury surface was
higher than a certain level, particles in the hearth floated up into the
raceway. This implies the possibility that the V-shaped cohesive zone
The behavior of solids in the lower part of the blast furnace is not well
understood because of the difficulties of investigation and analysis, in
spite of the importance in preventing hanging and slipping. In order to
estimate burden descent in the belly and the bosh, it is necessary to
understand the stress conditions in these regions. Therefore the stress
distribution has been studied using a model furnace, and the profile of
the dead coke zone has been theoretically analyzed by the slip lines of
Mohr's circles.
had only a small influence on the angle of internal and wall friction, as
seen in Figs 4.4.2 and 4.4.3. The angle of internal friction of glass beads
is constant at sizes greater than I mm diameter, and under dense
packing conditions the internal friction angle becomes 3 0 larger than
that for loose packing, as shown in Fig. 4.4.4.
- Crushed formed coke
] 501----t---±---+----I
n
.i:
o
~ 45r----t--~~~+--~
o Metallurgical coke
~
OJ
-< 40 '------7;---7:::----:1-':-6---:'20.
Particle dio Imml
-.
Chamatle brock
20 ---- - Slippery steel plole
r---- ~ _a __
- Gloss pl ate
Cru shed formed co e
t:--.
-
c 15 1--.
x Meta llu rgical coke
]
g
1-- ~ ..
..
f-- _. -><
~ 10 --- ~F'---
.
g>
-
5
« ~~ b....-·
o 8 12 16 20
Particle die Imm l
o 25
Q)
c;,
c:
<C
200L---0...J..-
5 --1L.0- - -1..L.5- - - - ' 2.0
Parti cle d ia meter fmm !
Fig. 4.4.4. Effect of glass beads size on angle of internal friction measured by
three axes compression method. 52
Bottom plate
Discharging pipe
Cylindrical model
Fig. 4.4.6. Stress distribution in the vertical direction just after packing with
sand. 39
On the theoretical analysis of stresses in the stack, Janssen assumed that the
stress was in the critical state for yielding and that the major and the minor
principal stresses acted in the vertical and the horizontal directions, respectively.
The horizontal stresses were considered to be uniform in the radial direction.
Considering the Mohr's circle in Fig. 4.4.7 on the above assumptions, the
ratio of the horizontal stress aH to the vertical stress av is expressed as follows:
K=
am - am sin ¢!i
am + am sin ¢!i
I-sin¢!i
(4.4.1)
1 + sin ¢!i
where K is a coefficient of earth pressure known as Rankin's constant.
FLOW OF GAS, LIQUID AND SOLID 357
D."!
. th e stack'Just a f ter packi ng.38
Fig. 4.4.7. Stress m
hence
H = KP (4.4.3)
A = 1T(R + h tan 8 sJ 2 (4.4.4)
Sw= 21T(R + h tan 8 sh ) (4.4.5)
where 11 w is the coefficient of wall friction and Pb is the bulk density of material.
Now if h = 0, then P = O. Equation (4.4.2) is integrated as
dh
cos Osh
Hcos Osh
ay, and vertical stress aH in the stack, and the coefficient of earth
pressure aH/ay under dynamic conditions. Large fluctuations of wall
stress a w occurred owing to intermittent descent of particles close to the
wall. a w increased gradually towards the lower part of the shaft and
decreased markedly after reaching a maximum at the belly. The striking
development of wall stress at the belly means that the active state of
stress field changes to the passive state.
'{I ndr col" dt; o~." 83
Coefl lclenl 01
corrh pre\!oute
Fig. 4.4.9. Changes of wall, vertical and horizontal stresses in the vertical
direction. 39
shows that the directions of the major principal stresses and the slip
lines are different at the various radial positions.
In Fig. 4.4.9, the shaded area shows that the coefficient of earth
pressure is about 1. In this area where material descends in funnel flow
toward the outlet, the stress condition is a completely passive stress field.
The action lines of major principal stress just after packing and in a
steady flow state are illustrated in Fig. 4.4.10, on the basis of the stress
distributions shown in Figs 4.4.6 and 4.4.9. The effect of the descent
velocity on the distributions of horizontal and vertical stress is not
apparent in Fig. 4.4.11. This means that the direction of major principal
(AJ just after packing IBI steady flow
A : Active state
B : Transitional state
C : Passive state
Fig. 4.4.10. Directions of major principal stresses just after packing and at
steady flow. 39
Horizontal slress
o 20 40 60 80 0 20 40 60 80 100
UH 19 / cm 2J "v Ig / cm 21
stress, as well as the slip lines which have angles of ± (1T /4 - 41;12) to the
lines of major principal stresses, is constant with different descent
velocities.
,,~
0"
o~
T ..:(,qj.
,,<
,<0""
!Trz1w --------------.----- ,........,=---
" wI
"
a r is 0, and the angle of internal friction for the particle is ¢i, the slip line
is generally expressed as follows:
- dz/dr = tan r (4.4.7)
r = 0 ± (JT /4 - ¢/2) (4.4.8)
The diagram for the direction of the slip line of a bed is obtained by
expressing 0 in eqn (4.4.8) as a function of the radius r.
Equations (4.4.9)-(4.4.13) are given from Fig. 4.4.12:
(t'rz)w = Xl sin20 w (4.4.9)
(t'rJr = X2 sin20 (4.4.10)
(4.4.11)
ah = xdl/sin¢i + cos 2l/fwJ (4.4.12)
20w = [¢w+sin-l(sin¢w/sin¢0J +28 (4.4.13)
(4.4.15)
(4.4.16)
1.2 r----.:--r;-~:_::_-____,
1.0
"N"" 0.6
The gas flow in a blast furnace governs the reduction of iron ore and
heat transfer to solids. Therefore it is important to know how the gas
flow is affected by changes in the furnace burden profile, caused by
variations in the fed materials and in the burden distribution in daily
operation. Gas flow in the furnace is affected by radial particle size
distribution, void fraction distribution and ore and coke layer thickness
distribution in the upper part ofthe furnace, by the shape ofthe cohesive
zone in the middle part, and by the shape of the deadman and the flow
resistance of gas through the deadman in the lower part.
Since the above problems have become important for modem blast
furnace operation, two-dimensional analysis is used as the basis for
calculation of gas flow. Numerical calculation of two-dimensional gas
flow has become possible by extending Ergun's equation8 for pressure
drop to two dimensions, and many examples of the calculation have
been reported. 55,56
However, these attempts have not been widely applied to commercial
blast furnaces. This is because the burden distribution and cohesive
zone distribution in the furnace must be numerically defined before
calculation of the gas flow, and this is difficult. In this section, an
attempt is made to calculate the two-dimensional gas flow by
combining a gas flow model with a burden distribution model in which
a degree of freedom is given to the furnace burden profile.
(4.5.2)
FLOW OF GAS, LIQUID AND SOLID 365
The profile of the burden top surface of the second and following
charges is given, as shown in Fig. 4.5.1, by a third-order polynomial ofx,
and the coefficients a to d are determined in such a way that the volume
of an ore layer, Vo, given by eqn (4.5.3) and the volume of a coke layer, Ve,
given by eqn (4.5.4) are satisfied.
Vo = !oc(CJPbo) (4.5.3)
Ve = CJPbe (4.5.4)
For example, the equation of the burden line g(x) in Fig. 4.5.1 is
determined by repeating the calculations of eqns (4.5.5)-(4.5.7) until eqn
(4.5.7) is satisfied.
e
a ] _ [X!'
X3, X3, X2]-1 [Y2]
X!' X3 Y3
[ be - (4.5.5)
Ce xl, X~, X4 Y4
g(x) = ae x 3 + be x 2 + CeX + de (4.5.6)
(4.5.7)
366 BLAST FURNACE PHENOMENA AND MODELLING
(4.5.11)
FLOW OF GAS, LIQUID AND SOLID 367
(4.5.12)
where
An empirical formula, derived59 on the basis of a combustion
experiment by using a model combustion furnace, was used to express
the shape of the raceway.
An empirical formula obtained with a cold model by Miyasaka et a/. w
was used to represent the shape of the deadman.
Figure 4.5.2 shows the boundary conditions for gas flow. The basic
concept is that gas blown horizontally through the tuyere passes
Gr cos 8+Gz sin 8=0
8=tan- 1 (f,lr)
3r=0
Gr=O
Gr=~Gin
Gr=O
Gz=O
Fig. 4.5.2. Boundary conditions for gas flow.
368 BLAST FURNACE PHENOMENA AND MODELLING
)1 H 1 1 1 1 1 I 1 1 1 1 Ii
,. 1" 1 1 J 1 1 1 1 I I I 21
)~ I'" 1 1 1 1 1 1 ) 1 1 I. 1 II
,. 1l1li 1 1 I 1 1 1 I 1 1 J 1 21
- ~: -- !:- ~ - ~-~-~~-!-~ - ! - t~ ~-! -~!------
H ,,, I 1 1 I 1 1 1 1 1 1 1 21
)0 1" I 1 1 1 1 1 1 1 1 1 1 11
.. t '" 1 1 1 1 I 1 1 1 1 1 1 U
•• ,.. 1 1 1 1 1 1 1 1 1 1 1 l;U
-:!--!:-!--t-l ~--t-!-~-!-t-t-!-~ ~~-----
.til)
..
.,
HI . ,
h
h _, _,
, . , -, - ,
.'1.,
1 I.
1
1
J
1
1 I.
1
1 1 J 1 I 11
1 l i t 1 1 11
I
1
1
I
1
1 1 U
4l 16" ., . , . , I I 1 1 1 1 1 U 1
_ '1 _ _ _ "" _ '_J _"'2'_ "'1_ "'Z _ .1 _ 1 _ 1 _ 1 _ 1 _ 1 _ 1 1_ __
I_
"0 1 " ] , ' - , .1 -1 1 I 1 1 1 1 1 I 21
). I" 1 ,) -, .. 1 .~"1 1 I. 1 I 1 I 1 21 _ _ _
,. l I t . ) , ) , -1 -2 _1 I 1 J L I. 1 I 21
II _ 1... , Jo , . 2 . ' _2 ) I L L I J J 2l
_ " ___1,,,_,_ )_
1I 1 . . . " " , ., .,2 · 2 -'1 1 1 I 1 I J 21
L~1 _ ·] ~2 _ _ ~I _ l _ l _ l_J _ 1J1_ _ _
loll h ) ; ) 1 ,..2 _2 ."·2 J I 1. 1 J 1 21
») h I~ ) l .).2.~ to :1 . :1 J 1 1 1 1 1 H
.*
II 1 " · ) ' . ) " . 2 .1 .1 ·1·2 1 1 J J 1 11 -
Jl I .. I~ ) :) } ) _2 .2 . 2 .1 -2 1 J 1 1 2l
JoO .~ -1 ) } ).:1 1 1 . , ·1.2 1 1 J i l l ." -
.u
21
I , .)
1'" .) . , . ) .) .)
I' -)
_ " _ _ 1'_·)_ _ ) __ l _ J _ J~22:1_·1--.!'1......!'2-..!2 _ 1 _ 1_1~1 _ _
J Jo ;) -2 .2 _1 -- 2 --2.1 1 1 11
,·~·1·1·1.2.1.2 -2 1 21
" 106 .) .) to,.) ,. ) , . 1 _ 2 . , . , _1 .1 "" . , ,~
ZJ
' II
,., 1" .) .). . ) . ,
h a~ .) . , . . ) )
I'll .) .) .) . ) .)
} ;) ) -1 .2 ., ., .1 _1 ., .2 10
;)
J
,
,
, . , -2 ., .2 ., ·2 .1 10
) . 1 . 2 . 2 . , . , __ 2 Oil 20
- " --1'- · )- ·)-·'- · )-·' - " ~ ) )
"- · '- "'1- . 1- .1- .,2 - .1 20
11 1_ . 'J. .) .) . , . ) . ) ,) ,) l . l . 1 . 1 . 1 . 1 . 2 10
10 I'll . ) .) .) . 'J. . ) . ) ) ) " 1 . 1 . 2 . ' . ' . 1 20
l ' . . I'll . ) .) .) .) .) .).~ ,) 1 " l . l . 1 . ] . , 1'9
11
h
1'" .~ .) .) .) .) .).. ) ;) l .) " ' . ] . ' . 2 I t
_ " _ _ 1. _. )_.)_.)~)-..!)_.' _. ~ _ ) _ ,, _ ' _ l _ :) _ )
1• • ) ., .) .) .) .) . ) . ) l J l l " " ••
_'-L' __
1, ._ .) .) . ) . ) .) .) . ) . ) ) l ) ) l 1 l'
I... 1_ . ) . ) . ) .) . ) .') .) . ) . ) ) " , l ).,
I, ..... ) .) . ) .) .) . , . ) . ) . ) 1 ) ) " ) 1'9
11 I"" . ) . ) . ) . ') .) .':1 .) . ) . ) . " ) ) ) )."
_ 1\ _ _ I. _·) _·)....: )_· ) _· )_ ·, _·) _· )_ · )_·" _ l_ R"~._ A"" _ lL--
10 I • • ) .) .) .) .) . '.1 .) .) .) .) "''''' H" A... ,.. I'
I"" . ) • ., .) . ) .) • ., .) .~ .) • ., III .... " IA ... A... 1'1'
._ ." .) . ) . ) .) . , . ) .) .) ." th ill' R_ All" I,
.'" . ) . , . ) . ) . " . ) . ) . ) . ) . , . ) IU IA" III ... U
• 1 ..... ) . ) ." ." .) .) .) .) ." .) . ) . ) J '1)
_ L _ _ l"_ · ~.)~. ) ..! ) _.)_ . >.-' 1....·..) _·) _ ·.}_·) _.)_ .)_..l _ l l -
.. 1. . . ) .) .) . ) .) .) . ') .) .) . ) .) . ) . , 1 I)
I' . ) ., . ) .) .) ., . ) . ~ .) .) .) . ) .) ,. I)
1 .... ) .) . ) .) .) .) . ) .) . ) . ) .) . ) .) .) I)
11 11 11 12' 11 11 11 11 11 .1 11 11 11 II 11 Jl
Fig. 4.5.3. Map for the attribution of each grid and each zone.
FLOW OF GAS, LIQUID AND SOLID 369
Fig. 4.5.4. Two-dimensional gas flow in blast furnace considered from the
cohesive zone (effect of the cohesive zone height).
In general, the gas at the furnace top tends to flow toward the center
due to the inclination of the burden top surface. Lower in the furnace,
the flow resistance of gas through the cohesive zone is high, and
therefore the average flow resistance of gas through the bed increases.
As a result, radial distribution of gas takes place in this zone.
370 BLAST FURNACE PHENOMENA AND MODELLING
101 0.3 C 0 Cc
Ibl High 07 Co ce
lei 07 Co 0_6 < c
Idl 0.3' 0 'e
low
lei 0.3 < 0 06 <,
'0 : Void fraClion o f Ore layer
! c : Void rrcction of coke loyer
IdJ leI
Fig. 4.5.5. Flow patterns of gas flow in the blast furnace with various void
fractions in cohesive zone and deadman.
FLOW OF GAS, LIQUID AND SOLID 371
The stream line distribution in the lumpy zone is almost the same in
all the cases (a)-(e). This means that the velocity distribution of the gas
stream flowing from the cohesive zone rapidly changes in the lumpy
zone according to the radial distribution of flow resistance.
Case I Case II
case III the burden distribution when the same ratio is small. Figure
4.5.7 shows the radial distribution oflayer thickness ratio corresponding
to cases I-III.
Figure 4.5.8 illustrates the distribution of calculated values of mass
velocity at the top of the furnace. The flow rate distribution along the
burden top surface is represented by A. and B represents the flow rate
distribution along a line 0·5 m below the burden top. The radial
difference in mass velocity is larger at plane A than at plane B. This
shows that the gas quite near the furnace top flows towards the center
due to the effect of the burden top surface. The difference in flow rate
4.0 r - - - - - - - - - - - - , - - - - - - - . ,
(D Case I
CZ; Case II
1u
3.0
CD Case III
..c
w _i
L
b u 2.0
=~
a ~
a
;§ 1.0
2 3 4 5
Center Wall
Distance from the center (ml
8
Case I.@
°0 2 3 4 5
Center Wall
Distance from the center (m)
Case I
4 Case II, IV
~
o
OJ
'0 ~
~ NE
·u . . . . . .
~ ~ 2
>
:!i (')
o
L
OL---~----~--~-
o 2 3 4 5
Center Wall
Distance from the center 1m)
The existence of the cohesive zone strongly affects the gas flow in the
lower part of this zone. However, both cases show the same tendency in
the upper part of this zone.
It seems that the gas that has flowed out of the cohesive zone rapidly
changes its course of flow to suit the gas flow resistance in the lumpy
zone.
50 , -- - -------,
(.e •...,
j tl'
Fig.4.5.1O. Radial distribution for gas flow velocity and mass velocity.
figure, (a) shows the actual radial flow velocity distribution, and (b) the
radial mass velocity distribution.
The difference between the isothermal and non-isothermal conditions
becomes small when the radial distribution is expressed in terms of
mass velocity.
The radial difference in flow resistance is small in the lumpy and
dropping zones. At the furnace top, the effect of the inclination of the
burden top surface is observed in the gas flow velocity distribution. The
gas velocity is high on the inner side of the cohesive zone, whereas it is
low within the cohesive zone.
Fig. 4.5.11. Example of calculation of gas flow in the W-shaped cohesive zone.
Fig. 4.5.12. Example of calculation of gas flow in the V-shaped cohesive zone.
4.5.5. Notation
Cb coke weight per charge (kg/ch)
Dp particle diameter (m)
foe weight ratio of ore to coke (-)
Fl viscous term in Ergun's equation (kgwt·s/kg 2·m)
F2 inertial term in Ergun's equation (kgwt·m·s 2/kg 2)
G mass velocity of gas (kg/m2 ·s)
p pressure of gas (kgwt/m 2)
r radius (m)
z height (m)
Rb radius of furnace body (m)
U gas velocity (m/s)
U mf minimum fluidization velocity of gas (m/s)
Vo volume of ore layer (m 3)
Ve volume of coke layer (m 3)
a inclination angle of burden surface (deg)
ao inclination angle without gas flow (deg)
Pp apparent density of a particle (kg/m 3)
Pg gas density (kg/m3)
Pb apparent density of bed (kg/m 3)
& void fraction (-)
¢ shape factor (-)
ljI stream function (kg/s)
J.l g viscosity of gas (kg/m·s)
In the upper part of the dropping zone, gas and liquid flow upwards and
downwards, respectively (counter-current flow region). In the lower part
of the dropping zone or around a raceway, gas and liquid flow across
each other (cross flow region). Attention has been paid to liquid flow in
the dropping zone in relation to abnormal phenomena in this part such
as hanging due to flooding. 61 As mathematical models are developed,
full information on liquid flow is required to understand the flow
distributions ofliquid and gas behaving respectively as consumers and
FLOW OF GAS, LIQUID AND SOLID 377
suppliers of heat in the lower part of the furnace, and the kinetics of
reactions such as Si transfer into metal in the dropping zone.
The features of gas and liquid flows through this zone, which is
divided into two regions - counter-current and cross flow - are
discussed here.
4.6.1.1. Holdup
(aJ In the absence ofgas flow. Total holdup (h I) may be expressed as the
sum of static holdup (h s), independent of liquid flow, and dynamic
holdup (hd) caused by liquid flow in the absence of gas flow.64 Although
equations for hs and hI correlated with physical properties of both the
378 BLAST FURNACE PHENOMENA AND MODELLING
hs = [ 20·5 PIg</J;dp2
+ 0·263 O"T(1 + cos(})(l _ e)2
J- I
(4.6.1)
2
hd = Ao JO.648[
6·05 [ PIVI d p'l's p,gd p'l's JOA85[ PilJd p </J2s JO.097 (1
3Ao3
+ cos (})0648
(1-e)f11 (l-e)3f1f O"T(1-e)2 (4.6.2)
where d p is the diameter of particle (m), g is the acceleration due to
gravity (mN), VI is the superficial liquid velocity based on empty
column (m/s), e is the void fraction, f11 is the viscosity ofliquid (Pa's), PI
is the density ofliquid (kg/m 3), O"T is the surface tension (N/m), and </Js is
the shape factor of particle.
Measured values of h s for metal in a dissected furnace were estimated
rather well by eqn (4.6.1) at () = 90° (see Fig. 4.6.1). Holdup values of
10
Metal PI =6800 kg/m 3
,.-..
0 cf=1.1 N/m
~ 0
~s=0.65
0
~
VI
0
E= 0.43
0
a. 0
:J
-0 5
0 0
.c. e
0°
.- u 0
90°
....":;j
(j) 0
OJ B 125°
%0
cPO 0
o 0
0 60 ~o 0
0
25 30 35 40 45 50
Harmonic mean diameter of coke dp (m m)
Fig.4.6.1. Relation between static holdup of metal and coke diameter, both
sampled from a dissected blast furnace; the lines represent calculations using
eqn (4.6.1).63
FLOW OF GAS, LIQUID AND SOLID 379
(4.6.4)
and h to is the total holdup in the absence of gas flow, !1L is the height of
the bed (m), !1Pw is the pressure loss with irrigated liquid (Pa). The
380 BLAST FURNACE PHENOMENA AND MODELLING
f:1P w
f:1L
£ + h t )2
= [kl( 1 - de f../gvg +k2
1- £
de
J
+ h t PgV 2
g /(£-h
3 (4.6.)
t)
6
Here de is defined by
l-£+h t 1-£ h
= - - + -t (4.6.7)
de dp¢s dl
where d l is the virtual diameter of a liquid drop given by
dIVPlg/(JT = 6·828(~ - 0·891)2 + 0·695 (4.6.8)
Since the measured pressure loss f:1Pd can be written as
f:1P d /f:1L = AVg + Bv~ (4.6.9)
the coefficients k 1 and k 2 for various particles and packing conditions
can be calculated from
k2 = B dp¢s 83 (4.6.11)
Pg 1 - 8
Holdup h t is already shown by eqn (4.6.3), and finally !l.Pw/!l.L can be
evaluated from eqn (4.6.6) at given values of v g (see Fig. 4.6.2).
.-.. 5.0
-E
ttl
a..
~
3.0
0
0
Experiments
by Gardner
- - Calculation
......,
<l 2.0
........
~
<l 1.5
-c
<11
1.0
1J
ttl
~
0.7
(]I
<11 0.5
~
:J
(/)
(/)
<11
a.. 0.3
~
0.2
0.15
0.15 0.2 0.3 0.5 0.7 1.0 1.5
For the dropping zone of a blast furnace where two liquid phases
exist, h t in eqn (4.6.6) is replaced by (h ts + htm), de is redefined by
(4.6.12)
382 BLAST FURNACE PHENOMENA AND MODELLING
20~----------~------------~
dp 4>s= 0.015 m
£ = 0.459
Flooding
VIs =7.0·1O-5 m/s
-5
Vlm =8.6·10 m/s FI ui d iZatiOnv
-E
It!
a.. .......
;;-
o
10
III s = 1. 0 Pa·s
III m = 0.005 Pa·s
I
I
/
6.Pw /
E
6.L /
~
..c:: /
/
Ci'1-J
<l<l ~
5
1.
..c::
~I-J
<l<l
6.~ .'_
6.L ••• -
----- ---- ---- --------------
OL-~~~-L~~--~~~~~~
10'
~
d,.. 5
<II
t1.
~.~
M
'0 2
..=. o 6> ~o
...cl
100
00 0&~*'e~6b~
F
5
~ ~ 8a~
...~~
Published works ... •
_M
2 - Lobo ~
" w --- Standish
:>:01
.
0
10-' •
o
"l
Elliott
Shavrin
Szekely
v 5
.!! Present work
01 • Wetting flow
C
"0 2 o Non -wett in g flow
0
~
LL
Fig. 4.6.4. Plot of flooding data 61. 62. 84-S7 on Sherwood diagram; at is the surface
area per unit volume of bed (m2/m3), 1'/ is the viscosity of liquid in cP
(lO-3Pa·s).62
384 BLAST FURNACE PHENOMENA AND MODELLING
10°
7
c:C 5
.....en
~
"- 3
cC'
<l
2 0
0
III
III
0 10- 1
...:>
GI
7 - - - Mersmann's correlation
III
III 5 - - Proposed correlation
~
a. • Wetting flow
I/l 3 o Non-wetting flow
III
GI
c: 2
o
III
c:
~ 102~--~~--~~~~__~~__~~~~__~~~~~~
a 10- 6
. d . ,~VI(l-e:) (cos~)2
Modified dimensionless irrigatIon enslty 3,f PI g2 dp £ 2
.......
E
- 7.5,-----------------------------~
~
...:
-.J 6.0
<1
.......
~
<1 4.5
III
III
o
3.0
...
CII
~
III
:::
... 1.5
a.
III
~ OL_~_L~_ _L_~_L~~_ _L_~_L~_ _~
(!)
10.5r-------------------------------~
Particle density: Ps= 920 kg/m 3
....... 9.0
*'
:
PI =1920
=0.0016 m/s
I::. : VI
;;! i 0: 0.0025
.c: ! <> : 0.00006
7.5
a.
~ ~
"0 ,tj.
"0 6.0 t::r •• ,'
.s::. 1::.-------
-
0
111
I-
4.5
3.0L-~~~--~~~~~~~~~~--~
Fig. 4.6.6. Variations of gas pressure loss and total holdup with gas velocity for
experiments with liquid of high density.62
0.5
Q o
w CXD
-
dn
I
o
0.4
'0
C1>
.0 Flooding
C1>
-
.L:
0 0.3 o
:>.
• \
()
0
o
\
til
c Fluidization
C1>
'0
til
til
C1>
c 0.2
0
til
C
C1>
Slag flow in
E blast furnaces
0
0.1
10-6 2
Experimental points:
0: normal flooding
(): fluidization together with flooding
.: fluidization before onset of flooding
Figure 4.6.3 shows that the gas pressure gradient (!),Pwl!)'L becomes
equal to the gravity force on liquids and packing,Fg, at a gas fluidization
velocity slightly lower than the flooding velocity, and that !).Pwl!)'L is
larger than Fg at higher velocities. Fluidization rather than flooding of
the coke bed is therefore expected to take place.
388 BLAST FURNACE PHENOMENA AND MODELLING
Isobar ------
~
mflTTqmm'r rr;l7Tm~777Tm fTI t~ f
I
I I
I !: I I
I /
/
f I: I /
I \ :' / /
\ \ / /
\
\\
\. . /
/
A\
---\-t-i l' -j\--fA
I
\ :' I,,
\:' I:,
I ,
!:: ("
o
580
~
(b)
t I
/--------1-----\
5 ,/' '"
I \
~ 0 O"'-";:'~--'-----1f_---'-',.:.::~""-......:.-.:..:--'--..J-
(a) (b)
all gangue was not considered to be derived from coke ash. Inflow of
slag to the raceway was therefore estimated to take place, and the
amount of influx was shown to be dependent upon operating conditions
and the particular situation of the furnace.
As stated in the last section, the occurrence of flooding in a blast
furnace is considered to be impossible. However, even if it is possible, a
certain amount of liquid will drop, according to the gas flow rate
390 BLAST FURNACE PHENOMENA AND MODELLING
through the bed and to packing conditions. This is why the absence of
liquid flow into the raceway and its vicinity cannot be attributed to
flooding. Liquid dropping into the raceway and surrounding area
should be treated as a problem of redistribution ofliquid in and around
the raceway or in the cross flow region.
(b) Liquid flow distribution. Narita et a1.,100 Nakagome et a/. 101 and
leschar et a1. HJ4 showed, from their raceway model experiments related
to liquid flow distribution, that the peak of liquid volume flux shifted
towards the center as gas flow rate and/or liquid flow rate increased (see
Figs 4.6.9 and 4.6.10) and that the position of the peak became almost
unchanged above certain values of gas or liquid flow rates.
-
ME
u
0.15
o
o
600
300
x
~
0.10
ell
E
:l
0.05
0
>
"0 ..... -0--0--0--0--0
:l
CT 0.0
....J
t Distance
Tuyere
Basic experiments in which water was dropped from the top of a bed
and gas flowed sideways were done by Ohno et al.,105 and the liquid
stream was observed by a visualization technique. The displacement
distance and variation ofthe liquid flow pattern increased as liquid flow
rate was raised (see Fig. 4.6.11). Such behavior is considered to result
from liquid holdup, and consequently actual gas velocity, increasing at
high liquid flow rates.
Kondoh et a1. 106 estimated, from the results of liquid holdup
distribution measured in the lower part of a dissected blast furnace, that
liquid velocity would be a maximum at the center and would decrease
FLOW OF GAS, LIQUID AND SOLID 391
toward the wall in the counter-current flow region. This was based on
the fact that the thickness of the ore layers in the vicinity of the wall
decreased with increase in cross-sectional area as burden descended
through the shaft. Liquid holdup distribution, shown in Fig. 4.6.12, was
--- Q( =5 l/h
15
25
Q g = 100 Nm3/h
Fig. 4.6.11. Variation of liquid flow pattern with liquid flow rate. 105
In\\\1
I V \ \ \ \
/ \\1\1
I A \'1 \ I
II U \ \\ \ I I I ~
>
~
3 3 4 4
8 6 5 6 0.4
~
2 2 2
5 10 7 6 6 a.
>-
6 7 5 0.2 Z
41)610 a.
>
....Ql 3 3 3 8 9 6 8 8 0
-
0 .0
nI
18 18 8 6 7 6 8 7
.c
16 17 7 5 8 5 6 6 01
0.2 'iii
.c
66 18 17 12 7 8 8 6 III
III
43361219 7 7 6 4 0.4 a.
0
0 C
0
~
25 18 14 9 9 5 6 6 'iii
l- c
II 18 21 2219 23 4 6 0.6 a.
E
I I I I I I I
i5
o 0.2 0.4 0.6 0.8
Dimensionless distance from tuyere
Fig. 4.6.12. Distribution ofliquid holdup measured in and around the raceway
of a dissected blast furnace. 106
392 BLAST FURNACE PHENOMENA AND MODELLING
1 Air
Water
75 Nm3/h
60 II h (total)
1
Fig. 4.6.13. Observed flow pattern ofliquid coming from one cohesive layer. \07
~
I
E
u
2.0
6.0
E
u
Il">
~
10.0
14.0
18.0
E
u
o
('oj
22.0
60 em
Kajiwara et al. 108. 109 analyzed the same subject using the following
equations:
Gas phase
Equation of continuity:
o (4.6.17)
Modified Ergun8 equation:
Liquid phase
Equation of continuity:
o (4.6.19)
394 BLAST FURNACE PHENOMENA AND MODELLING
Liquid holdup:IlO
ht = hs + hd = 0·03 + 0·147v?·676 (4.6.21)
The boundary of the dry zone was determined experimentally. Figure
4.6.15 compares the calculated water flow distribution at the bottom of a
bed with experimental data.
O.2.---------------------------~
-
........
11)
____ Calculated
E
u 0---0 Measured
:>. 0.1
u
o
Qj
>
...
....<IItil
~ O.O~~--~----~----~----~--~
0.0 0.2 0.4 0.6 0.8 1.0
Dimensionless distance from tuyere
Fig. 4.6.15. Water flow distributions at the bottom of a bed.108
Iron and slag accumulate in the hearth and are tapped out of the
furnace through a tap hole. Although production is continuous, tapping
is discontinuous and hearth drainage has been one of the major
concerns of blast furnace operators, since good drainage and the
resultant dry hearth are essential for good furnace operation. Blast
furnace operators frequently experience a sharp increase in blast
pressure followed by irregular burden descent when the amount of
residual liquids in the hearth increases. Excessive accumulation of
liquids is pointed out to be one of the causes for large slips which are
followed by disastrous hearth chilling. ll3
In the cast house practice of a modern blast furnace, the cinder notch
is not used any more and all molten products are removed through a tap
hole. During tapping, slag and metal in the hearth flow towards the tap
hole and then out through it. Although the possibility of flow induced by
natural convection has been pointed out,"4 forced flow during the
tapping period dominates flow phenomena in the hearth since tapping
is done more or less continuously in modern blast furnaces. Although
396 BLAST FURNACE PHENOMENA AND MODELLING
The size of the raceway does not change substantially with blast
furnace size and the relative size of the raceway zone decreases as the
furnace size increases. Therefore the coke bed is more likely to sit on the
hearth bottom in the case oflarge furnaces, and more likely to float in
the case of smaller furnaces.
It is estimated that, in the hearth of modern blast furnaces, the coke
bed is more likely to penetrate deep into the metal bath. However,
quantitative evaluation of the penetration depth is difficult and the
results of the dissections could be different from those of operating
furnaces.
Although no direct observation was made on the state of the hearth,
the study of flow phenomena in the hearth by use of a radioactive
tracer I 16 revealed that both states of the coke bed, sitting on the hearth
bottom or floating, existed in the same furnace, but at different periods.
It was also found that the penetration depth of the floating coke bed was
such that it penetrated through the slag into the iron, i.e. the slag always
accumulates and flows in voids within the coke bed.
Thus, in the case of large blast furnaces, as shown in Fig. 4.7.1, the
state of the coke bed is such that
(i) slag flow can be treated as flow through porous media;
(ii) metal flow can be treated as flow in a container that is partially
filled with solid particles and has a free flow channel underneath
the packed bed (Fig. 4.7.1 a); the depth of the flow channel can be
decreased to zero to form a complete packed bed (Fig. 4.7.1 b).
Fig.4.7.1. Schematic representation of the state of the coke bed in the blast
furnace hearth.
1.0
1/
-;)1;;-
Ry
.
" 0.8 r-- 0 <2.5
o /). 2.5-5.0
'206 r--- 0 5.0 10.0 ,
-I--
o (r 10.0<
~ 04
:D
'"
oo~I
0.2
--- .. -......... ~~ ca
where s is the bed porosity (-), ¢s and d p are respectively the shape
factor (-) and the diameter (m) of coke in the hearth, f.ll is the liquid
viscosity (Pa's), PI is the liquid density (kg/m3), Vo is the liquid velocity
(m/s) averaged over the empty cross-sectional area of the hearth, g is the
gravitational acceleration (mN), and DM/HM is the ratio of the hearth
diameter to the depth of the liquid layer of the model.
~
~
~
~o
~
~
Liquid outlet
~'.
Photo.4.7.1. Inclined liquid surface formed during liquid drainage in two-dimensional (left) and three-dimensional
U.)
(right) models.
:g
400 BLAST FURNACE PHENOMENA AND MODELLING
It can be seen from Fig. 4.7.2 and eqn (4.7.1) that the residual ratio, a,
increases as
(i) the velocity, Vo, of the liquid increases,
(ii) the liquid viscosity, /Jb increases, and
(iii) the permeability of the coke bed decreases.
Since the viscosity of pig iron is 1/100 that of slag, the residual amount of
pig iron is considered to be significantly lower than that of slag.
The relation shown in Fig. 4.7.2 was combined with a mass balance of
slag in the hearth to estimate the influence of tapping conditions on the
residual amount of slag. 118 As an example, the influence of slag viscosity,
/J" and slag tapping rate, P" on the amount of residual slag, Wn at the
end of tapping is shown in Fig. 4.7.3, and on the depth of the slag layer,
H" at the beginning of slag tapping in Fig. 4.7.4. These figures show that
both the amount of residual slag and the depth of the slag layer increase
with an increase in either slag viscosity or slag tapping rate. An increase
in the number of tappings is effective in decreasing the depth of the slag
layer. Figure 4.7.5 illustrates that the depth of the slag layer is kept
constant by an increase in the number of tappings when the slag
tapping rate is increased; for a constant number of tappings, the depth
of the slag layer increases with the slag tapping rate.
Quantitative evaluation of the influence of tapping conditions is
made by using the approximate correlations I 18 shown by the following
two equations
~ 2001--+----+--+---+-----1 Ps
4.0
:i 1--+----+--+-:7""=+---=....-4 3.5
g 3.0
:;;; 1501--+-----;;>....qc:;7"'-=--+-:;;....-=t------:::;j 2.5
o
~
~ 2.0
~
a
c 100 1----=--+::....-=\---+---+--==-1 1.5
o
E
«
50~_~_~ __ L-_-L_~_~
Fig. 4.7.3. Influence of slag viscosity and slag tapping rate on the amount of
residual slag.
FLOW OF GAS, LIQUID AND SOLID 401
Fig. 4.7.4. Influence of slag viscosity and slag tapping rate on the depth of the
slag layer.
>- 40
"
"0
iii Ws
] 30
-- 2400
---------- 2100
---- 1800
--
.'
Z 1500
<Ii 1200 ,.-"''''''
20
01
C
.8 10
"0
~
'E"
.n 0
::J 1.0 2.0 3.0 4.0 5.0 6.0 7.0
Z
Rate of slag tapping. Ps (t/min)
Fig.4.7.5. Relationship between number of tappings and slag tapping rate to
keep Hs constant.
where Hs andH r are the depth of the slag layer at the beginning and at
the end oftappihg respectively (m), Nt is the number of tappings (l/day),
DT is the hearth diameter (m),P sis the slag tapping rate (t/min), Ws is the
slag production rate (t/day),,us is the slag viscosity (poise), andA andA'
are proportionality constants. The influence of coke bed permeability is
evaluated by substituting ,us for the flow resistance,A, of the bed:
1
(4.7.4)
402 BLAST FURNACE PHENOMENA AND MODELLING
B~--~--~----.-----.--.----__---r--~A
101
B~__~G____~___F.-____~~____. -__~__~A
G'
0--- c
Ibl
Fig.4.7.6. Flowpattem of iron in the hearth for~aJ. 'sitting on' coke bed and (b)
the 'floating' coke bed. 1 ,120
solidified layer on the hearth bottom. A model study of the growth and
decay of the solidified layer showed an important role of the flow
channel underneath the floating coke on heat transfer to the hearth
bottom.
5
I
101
4 -
3 - oj
I
•.....
2 - r-=-In (1- 5")
1 - /0
t:.0
~
0 1,' I. I I
0 0.5 0·9 0·95 0.99
s·
Ibl
C10
E
..... e
ClI
E 6
.....
ClI 0
g 4
j
ClI
-0
'in
ClI 2
a:::
0
0 0·5 0·9 0.99
s·
Fig.4.7.7. Relationship between residence time and the dimensionless
parameter S* for (a) the 'sitting on' coke bed and (b) the 'floating' coke
bedY9.120
FLOW OF GAS, LIQUID AND SOLID 405
lilll
-
law is applied:
Kv
VI - - grad <I> (4.7.7)
fJI
The equation of continuity is shown by
-
div(v I) =0 (4.7.8)
where -; I is the superficial liquid velocity (m/s); Kv is the permeability of
the bed defined by
Kv = £3<p;PIg/[180(l - £)21 (4.7.9)
the slag for constant tapping rate would be significantly smaller than
that for variable tapping rate, when the average tapping rate was the
same for both cases.
REFERENCES
1. H. Nishio and T. Ariyama, Tetsu-to-Hagane, 68(1982),2330.
2. R. L. Brown, Nature, 191(1961),458.
3. H. Nishio, T. Ariyama, K Wakimoto and A. Yamaguchi, Tetsu-to-Hagane,
68(1982), 1523.
4. K Narita, S. Inaba, I. Kobayashi, K Okimoto, M. Shizu, T. Yatabe and
S. Tamada, Tetsu-to-Hagane, 65(1979), 358.
5. F. A. Yushin and N. N. Babarykin, Stal in Eng. (1964),850.
6. T. Sugiyama, M. Nakamura, T. Uno and Y. Hara, Tetsu-to-Hagane,
62(1976), S39.
7. H. Nishio and T. Ariyama, Tetsu-to-Hagane, 66(1980), 1878.
8. S. Ergun, Chern. Eng. Progr., 48(1952),89.
9. J. P. Metcalf, Int. J Rock Mech. Min. Sci., 3(1966), 155.
10. Y. Mori, Ohyo-rikigaku, 4(1951), 42.
11. Y. Togino, S. Kume, M. Tateoka, S. Amano and I. Abe, Seitetsu-kenkyu,
288(1976), 11842.
12. R. Ando, T. Fukushima and S. Kishimoto, Tetsu-to-Hagane, 57(1971),
S661.
13. T. Izawa, M. Miure, K Satomi, M. Saito, T. Miyamoto, T. Fukushima and
T. Furukawa, Tetsu-to-Hagane, 63(1977), S446.
14. K Narita, S. Inaba, M. Shimizu, I. Kobayashi, K Okimoto and
A. Yamaguchi, Tetsu-to-Hagane, 66(1980), 459.
15. M. Higuchi, Short Course Blast Furnace Burden Distribution, presented
at ISS-AIME Ironmaking Conference, Chicago, 1978.
16. M. Ikeda, H. Yamawaki, O. Kojima, K Satomi, T. Shibuya and B. lino,
Nippon Kokan Technical Report, Overseas No. 28 (1980), 11.
17. M. Kondoh, K Okabe, 1. Kurihara, K Okumura and S. Tomita, Tetsu-to-
Hagane, 63(1977), S441.
18. M. Kondoh, Y. Konishi, K Okabe, S. Tomita, S. Hashizume and 1.
Kurihara, Blast Furnace Conference, ArIes, France, June 2-4, 1980,1-3
19. M. Kondoh, T. Koitabashi, K Okabe, H. Marushima, H. Takahashi and 1.
Kurihara, Trans. ISIJ, 20(1980), B-251
20. S. Miwa, Report of Powder Technology Society of Japan, 1960, No. 26.
21. J. Kurihara, H. Takahashi, H. Marushima, T. Nagai, S. Tamura and
M. Kondoh, Ironmaking Proc., 38(1979),406.
22. J. Kurihara, S. Hashizume, H. Takahashi, H. Marushima, M. Yasuno and
K Okabe, Ironmaking Proc., 39(1980), 113.
23. T. Izawa, M. Miura, K Satomi, M. Saito, T. Miyamoto, T. Fukushima and
T. Furukawa, Tetsu-to-Hagane, 63(1977), S446.
24. K Yoshimura, T. Sato, S. Fukihara, S. Shimazaki, K Narita, M. Maekawa
and H. Kanayama, Tetsu-to-Hagane, 64(1978) S551.
25. K Kambara, T. Hagiwara, A. Shigemi, S. Kondo, Y. Kanayama,
K Wakabayashi and N. Hiramoto, Tetsu-to-Hagane, 62(1976), 535.
26. S. Kazikawa, N. Sumita, E. Yoshikoshi, T. Fukushima, T. Kamoshida and
T. Furukawa, Tetsu-to-Hagane, 59(1973) A81.
27. T. Izawa, N. Sumita, S. Kazikawa, T. Fukushima and T. Furukawa, Tetsu-
to-Hagane, 62(1976), S64.
410 BLAST FURNACE PHENOMENA AND MODELLING
414
HIGH TEMPERATURE PROPERTIES 415
E 15 0) E
E ,525 b) In~I~~~~~
800·C c:
~==o~~.... - - . ----0- el5-2o.mm
-°_0_ 700.C
.Q
,g
t:
~~ -0 2 0. £l10.-15mm
0,
~ ... 8-lo.mm
o lo.~""""""C) '0
D 5- 8mm
-6 ~~ - 6OO·C ~15
...
~... ~o
-'-o().... 575·C
..... ~Io.
o ,.~
o~
~~
5 550·C
Q)
N
-,525·C .~ 5
'iii t:
c: " o.~::-±-::...."....,="",,,+~,.,.J
o ~ 0. 0..0 5 0..10. 0..15 0.20
~ 0.o.~""'o..~o.5=-=-o..':-:lo.~o..""15:-o.::'20=-Co.=':.2::::5""'o.::".:.30:-=-:o.='=.35:-:-::o.~40=-' Reduction degree f5 (- )
Reduct ion degree f 5 (- )
E E
,5 25 C) Co.% ~25 d )Gos flow ltIlelNIitnIn)
c: 020. .Q 05
2o 20
.25 ~ -Y' elo.
030. ~"" 0 15
~- £I 35 .., £120.
~ 15
... )5 ... 40.
045 ~
... 25
030.
=o _ 50.
~IC~-o
Q)
:!l
'iii
.~ 5 ")f"6~
c: t: t:
g 0. g 0. a< o.~::-±-::""""""""",.-J:,-~~
::;: 0. 0..05 0..10. 0..15 0.20 ::;: 0. 0..05 0..10 0..15 0.20 ::;: 0. 005 0..10. 0..15 0.20.
Reduction degree f5(-) Reduction degree f5(-) Reduction degree f5(-)
T:> 798K
a = exp( -9' 55 + 12200IT)(DSo/12'75t31(RDI/25-7t57 (5.1.2)
b exp( -8-08 + 10 2101T)(DS o /12'75)180(RDl/25'7)165 (5.1.3)
T < 798K
a = (3'10 X 102)(DS o /12-75f31(RDl/25-7)2.57 (5.1.4)
b (1'11 X 1Q2)(DSo /12'75Y89(RDl/25'7r5 (5.1.5)
These equations were applied to the blast furnace simulation model
which was obtained by assuming uniform heat and material flow in the
radial direction, and the size of sinter was calculated at the lower
boundary of the indirect reduction zone. The calculated results were
compared with the blast furnace operation and the relationships shown
in Figs 5.1.2 and 5.1.3 were obtained.
416 BLAST FURNACE PHENOMENA AND MODELLING
20~----------------------------~
-,.,
o
15
~
,,~
"" E
~ E
..
.0
~
10
~
o o
"
.. N
£: o"
a t;
o 5
~ f
V> "o
-u;c:""
~;:::
., 0
~
°1'::5---::2:'::0--::2:'::5,....--:3::LO~-:3,J:5~-4.,.0"....----J4L,,-5-....J50L----J55
R0 I (- 3 mm % )
Fig. 5.1.2. Relation between the sinter size at the shaft level and ROI.
16
4_
,
... .,\. . -.. . V
.A
480
•• !t
f.: •.. ,1.4
J1 470 ~
.•.,.• ...... r-,if.
N
0
iE'i •. ~ 12
~'I1~r.-=--:"
.~
............. .
0
~460 u
-.Fl. ~.. 0
';450 .~,. 10
.=
'g440 .
~
0
U "'08
~ 430
0 0
~
u ~
420 060
0 5 10 15 20 5 20
Sinter si ze 01 Ine lower boundary of Sinter si ze 01 Ihe lower boundory of
indirect reduction reaction zone indirec I reduction reaction zone
(mm) (mm)
(0 ) ( b)
Fig.5.1.3. Effect of sinter size at the shaft level on the fuel rate and the top gas
ratio.
HIGH TEMPERATURE PROPERTIES 417
As shown in Fig. 5.1.2, the sinter size at the indirect reduction zone is
large when the degradation index during reduction (RDI) is small and
the reducibility (JIS reduction degree) is low.
When the permeability has to be improved, a larger size of sinter is
required at the indirect reduction zone. Hence, the quality of sinter must
be low in JIS reduction degree and also low in RDI. On the other hand,
as shown in Fig. 5.1.3, the fuel rate becomes lowest when the sinter size is
at the specific value of 10-12 mm at the lower boundary of the indirect
reduction zone.
Therefore, if one can control the TIS reduction degree and the value of
RDI to satisfy the above condition, the fuel rate will be expected to
become low. For example, when the RDI is 40%, the suitable JIS
reduction degree is in the range of 67· 5-70%.
This is just an example; if the relationship is investigated in more
detail corresponding to the actual furnace, it will become possible to
estimate the suitable sinter quality corresponding to the blast furnace
conditions.
1 - (1 - 1,)113 == dk t (5.1.6)
po
TABLE 5.1.1
Testing Conditions for Reduction
TABLE 5.1.2
Calculated Values of Reaction Rate
Constants
estimated regardless of particle size. The rate constant (k) for any
particle size (d po ) can be obtained from the equation k = k'ld~o-l.
Average reaction rate constants have been calculated for the usual
burden materials by eqns (5.1.7) and (5.1.8):
(5.1.7)
(5.1.8)
The relationship between the gas utilization ratio in the blast furnace
and the mean reaction rate constant was introduced by the use of Rist's
diagram; they were also compared with the actual operational data.
The actual relationship between the change of kay due to the kind of
lump ore (~kav) and the change of the gas utilization ratio in the blast
X Sinter
o Goa ore
3.0 e India ore
.c:
"-
E
E
->:: 2.0
-
c
~
<I)
c
0
u
~ 1.0
0
0::
Rate constant corrected by
part i c Ie size
--0-------0------------ 0 - -
--x------- x------,.;0----- X--
--e- ------e------
O~------_L ________
e-----e--
L ________L______~
5 10 20 25
Particle size (mm)
A"lCQ (%)
Qbserved va lue •
• Chiba NQ.3 SF 2
0. Chiba NQ.6 SF
~--1-----+-~--~----+·~---+--~Akav
-0..2 0..1 0.2 (mm Ihr)
Fig. 5.1.5. Relationship between the change o.f rate constant (~kav) and the gas
utilizatio.n ratio. (~l1co)'
5.2.1. Changing of Mineral Phases During Reduction8, 10, II, 14, 16,20
After charging into a blast furnace, iron ore agglomerates such as pellets
and sinter, change their structures, as shown in Photo 5.2.1. In the upper
part of the furnace, the agglomerates are reduced by gas topochemically;
HIGH TEMPERATURE PROPERTIES 421
~ ~
..~
.§
o 3.0-
~
8 k 0 =-0.171 (FeO l+ 3.89
~ 2.0-
o
0::
I I _ _.l...-_...1...._......I.
1.0 L..-_...I...._--l. I I I_ _.l...-_-'
I
3 4 5 6 7 8 9 10
Fe 0 (%) ins i n t e r
the outer shell of the particles is converted to metallic iron, wustite and
gangue minerals, while the inner core is composed of wustite and
gangue minerals. When heated at high temperature, the metallic iron
and wustite undergo grain growth, and some melt is generated, which
produces phenomena such as retardation of reduction, softening and
cohesion. Furthermore, on reaching the higher temperature zone in the
furnace, a considerable amount of molten slag with a low melting point
exudes from the particles (due to the load), filling the voids in the layers
of burden material. This causes a decrease in the fractional void
volume, and results in a high pressure drop in the cohesion zone. Next,
because of carburization of the metallic iron, the agglomerate particles
melt down, and at the same time slag/metal separation takes place.
The above process is greatly affected by the kinds of burden
materials, and their chemical composition and mineral phases.
Therefore many investigations have recently been carried out into the
behavior of burden materials from reduction to melt-down. In this
section, in order to understand this behavior from a microstructural
422 BLAST FlJRNACE PHENOMENA AND MODELLING
U
10 IO~
....ex:>
III
MM
..... ;
......
......
U
10 10 0
....r-- N~
-
~
U
10 .00
0
<.0 O~
~e
point of view, the fundamental change in mineral phases and the melt
formation process will be described first, dividing them into several
stages such as induration, wustite formation, metallic iron formation
and the overall reduction process during heating.
5.2.1.1. Induration 9
Figure 5.2.1 shows equilibrium mineral components as a function of
basicity (CaO/Si02) and MgO content, when synthesized samples of
MgO-A1203-Si02-CaO-Fe203 systems are heated in an air atmosphere
at l250°C. According to Fig. 5.2.1, with an increase in CaO/Si0 2 the
amount of calcium ferrite increases, but amounts of hematite,
magnetite-magnesioferrite solid solution (M phase), and glassy silicate
MgO-AI,03-SiO,-CaO·Fe,03 system
100
S
50 MgO=2.0% H
t2
1
0
100
M
S
----
u
0 50 MgO=15%
en H
~ M
"6 0
S; 100
a
-"
Q.
a 50 MgO=IO%
~ H
E M
0 0
c 100 S
~
0
U 50 MgO=05%
M
0
100 S
50 MgO=O%
H
0
10 1.3 16 19 2.2
CaO/SiO, T.Fe = 60%, AI,03·- 1.5%
100~======~===c==~C_0r-C~0~'_IS~0~S~01
so CaO/SiO,= 1.6 W
MgO=lS%
1 C,S
~ so w
<1> CaO/SiO, = 1.6
" MgO=O.S% "
~ 01-.-'>-----+-----+-------"-+1
a liq
c c,s
~ SO" W
E CaO /SiO, = 1.3
<{ MgO= 1.S%
Ohr~>-----+-----+-----+l
liq
,
O~~~---~--__- L_ _~'WU
1200 1250 1300 1350
Temperature lOCI
50
C~S Li~ slag
CaO"Si02=1.6 M.Fe
MgO= 15%
0
# --- -- --
1 /
S~lid silicate
50 C,S
:li
0 CaOiS,O,=1.6 M.Fe
-"
D-
MgO=05%
'0 0
c - ---
"E0 /
C;S Solid silicate
I
Llq slag
« 50
CoO. SiO, = I .3 M.Fe
MgO=15%
0
----;------Tl
.i /
.
C,S Solid silicate
/
Liq slag
50
CaO/SiO,= 1.3 M.Fe
MgO=O.S%
0
1300 1350 1400 1450
-- ---
Oxygen
~ Hematite
-
/
.1
/
/
~-
~
~
/
/
Shell-core ')
/
:ll /
/ boundary,j'
Magnesioferrite-/
1 Magnetite s.s //
Wustite
"- 50 /
'0 /
/
c ,/
0
E
/
/
--Calcium ferrite
«
\ag----
O~-=~~~--~--~--~--~ __~
800 900 1000 1100 1200 1300 1400 1500
Temperature lOCI
Reducing gas: COIN, 130/701, 21/min
Heating rate : R.T --lOOO°C, 10°C/min lOOO°C-1500°C,5°C/min
Photo 5.2.2. Macro and microstructures of vertical section of packed bed lO (a)
1200 DC (core + metallic shell); (b) 1300 DC (metallic shell); (c) 1360 DC (surface);
(d) 1360 D C Qeft: core, right: surface). White: M.Fe(M); grey: wustite (W); dark
grey: slag (S); black: pore.
c
o
.~
~
60 120 180,0 60 120 180,060 120 180,0 60 120 180
Time Imin.1
(a) at constant temperatures
Ibl during heating
Fig. 5.2.5. Reduction curves of various pellets and sinter at high temperatures. II
For pellets G, with a lower slag content and a lower basicity, the
reduction rate is greatly reduced at l200 0c. Furthermore, the reduction
behavior of self-fluxed sinter H is similar to that of pellets, and a
decrease in reduction rate is obselVed at temperatures of 1200-1250°C.
However, the degree of retardation is smaller than that of pellets E.
With regard to heating rate, every sample shows retardation of
reduction at rapid heating rates, especially 7°C/min, but the retardation
degree depends on the burden material.
Figure 5.2.6 shows the influences of basicity and slag volume on the
retardation of reduction.
Photo 5.2.3 gives the microstructure of pellets E which were reduced
at 1250 °C for 30 min and which show a strong retardation of reduction.
It was found that metallic iron particles were sintered to a thin shell at
::r::
TABLE 5.2_1 0
-
Chemical Composition of Samples ll ::r::
...,
m
Chemical component (%) ~
"tl
Mark Sample CaOlSi02 Slag m
T_Fe FeO SiD 2 CaO Al20 3 MgO concn. (%)
E Self-fluxed pellets 60-20 0-20 4-50 5-50 2-10 0-40 1-23 12-10 ~
~
F Self-fluxed pellets 63-50 2-83 3-42 1-35 0-13 1-21 7-60 "tl
G Acid pellets 63-18 0-79 4-20 0-82 2-41 1-19 0-20 7-48 ::tI
H Sinter 55-15 8-60 6-45 10-09 2-40 0-59 I-56 18-94 0
"tl
m
~
m
rJl
~
430 BLAST FURNACE PHENOMENA AND MODELLING
100
EI 5.C.=7% E2 5.C.= 10% E35.C.=13%
80 B=1.0 B=1.0 B=1.0
60
~ 40
Q)
~
CJ)
20
Q)
"0 0
"
.Q
100
U 80
::>
"0
Q)
'" 60
40
Time Imin.!
S.c. : slag content B :bosicity
the pellet surface and molten slag with fine wustite particles was
generated near the inner surface of the shell.
The retardation of reduction is related to the state of the metallic iron
shell and the slag melt which blocks pores in the agglomerates.
Accordingly, the reduction behavior of pellets at elevated temperature is
different, because of the differences in the slag level and composition.
....
I/)
I...
o
0.
QI
.c
tI)
....
I/)
I...
o
0.
QI
I...
o
U
calcium ferrite; (D) hematite, silicate slag with high basicity and
calcium silicate.
From Photo 5.2.4, it is clear that the grain size of metallic iron grows
by coagulation in the external part of pellets A, and slag melt exists
among these metallic iron grains. In the case of B, a thin compact
metallic iron layer is formed, and the boundary of this layer and the
unreduced core is clearly visible. In the case of C and D, metallic iron
phases do not grow by coagulation, but remain finely dispersed. Only a
small amount of slag melt is observed in D.
On the other hand, from the results obtained by EPMA on slag
phases of the core (Fig. 5.2.7), it is clear that fayalite (2FeO. Si02 ; m.p.
1200°C) and iron calcium olivine (2(Ca xFe l -xO)Si02; m.p. 1100-
1150°C) are formed for pellets A and B, respectively. Slag phases of
types C and D consist of dicalcium silicate containing 4-9% FeO and
21-25% FeO, respectively, with corresponding melting points of about
2000°C and 1400-1500°C, respectively.
5iO,
Fig. 5.2.7. EPMA analysis of the slag phase in pellets with typical bonding
structure, reduced up to 1260°C by softening test under load.'2
35 ~
§' 1\0
_ 30
~
., 25 c\
\e
<::
.o
"
~ 20
<::
o
~
..
U 15
o~fo
10 "00.
5
o 0.5 1.0 1.5 2.0
MgO content (%)
o ____ _
" :). Mf
_ 20 ',,f \ J I, \ "
~
Ql
g'
I Hemotlte ore
40 M F MognoSiofernt.
J low bo,Iclly ,log
\ \ :.
\ ' : K
~.J
II
\
\ I
'>
r "
'S 60 J' low bosiclly "og IMgO 9 9%1'. ...... :-... \ ..
~ K Middle 00"'1)' , og IMgO I 8%1 \1, \ -- /' - - - =:: ~
l Colciumferrlte '~, • t
80 L' CO!clUmferfll. lMgO 4%1 \ \.
100 N H,gh bo,.c'ty slog , "-
1000 1100 1200 1300 1400
TemperOlure 1'0
TABLE 5.2.2
Synthesis Conditions of Sample Minerals ls
I 99'8 1300 5
MF 90·0 10·0 1300 5
J 30·2 24'3 45'5 0'53 1300 5
l' 24·1 22'5 43' 5 9·9 0' 52 1300 5
K 15'3 41'7 41'2 1·8 1·01 1300 5
L 78·4 18·7 2'9 1220 5
L' 75'3 17'9 2-8 4·0 1220 5
N 24·3 43-5 31'7 1-37 1300 0'17
I, Hematite are; MF, magnesioferrite; J, 1', low basicity slag; K, middle basicity
slag; L, L', calcium ferrite; N, high basicity slag.
HIGH TEMPERATURE PROPERTIES 435
T. Fe =60%
AI,O:l~ 15%
~ CaO/SiO,MgO wustite
(, 16,0.5 51ntered at 1280'C
u 1.6,1.5 In CO/C0 2 150/50)
~0 50
U
t> solidus temperature
IOOL---~I~IO~0----------~1~20~O~----------IS~0~0---------L-1~40-0--~
Temperature ICC)
2800
"-
2400 "-
e~
2200
"-
"-7tz- "-
"-
~ x "-
0 2000 (' "\
"
'\
a. '\
,,
E '\
~ 1800
>- "\
1600
Mognesio-Wustite \
1400
1200
o 20 40 60 80 100
MgO FeO
J-li-
1600
101 Ibl lei
1500
2
~ 1400 - ~~ Ak
£1
~ ~
;;
~
0.
j 1300 -
0--0 MIIMgO:06S1
1200
.........
<>---<> M2 IMgO : I 101
M3 11-.'90 : 2251
M4IMgO:3<181
.....-...
~
M5IMgO:.411
1/00
o w ~ W WOW ~ W MOW ~ W W 100
Prered1JCllon degreE" t%I
1:1:1
c §
E
o i
Q
w ~
::I:
~
~
~
>
c ~
E ~
o
0')
~
Photo s.z.s. Cross-section of prereduced pellets and sinter after heating up to 1300°C.14
HIGH TEMPERATURE PROPERTIES 439
Heatin~ temperature COC)
0
rl
rl
N
V)
"..
N
U
N
"0
<J
0
~
...co
""
5i0 2
WEIGHT %
Pellet X 60-61 <0-10 1-49 1-47 4-11 5-60 1-36 Dolomite ~'1:l
tTl
aSample sinter U and pellet X were made with industrial apparatus_ Others were made with a testing pot. §
tTl
(Il
t
-
442 BLAST FURNACE PHENOMENA AND MODELLING
disappears and the composition of the melt varies along the two-
components eutectic line of2CaO.Si02-FeO to point M. At this point,
2CaO.Si02 disappears and the composition of the melt becomes the
mean chemical composition N of the unreduced core.
room temp.
Qi -ci}
~ ~
1220·C ~
1240·C
W :Wustite
Mel: Melilite
C,S: Dicalcium silicate
30 35 40
28 (Degreel
Fig. 5.2.14. X-ray diffraction figures (eu K,. radiation) for sinter U reduced to
wustite after magnetic separation. 17
_2CoO.5iO, 60 FeO
1380
0;
room temp.
2 ~
0;
2
1150'C
.£ 0;
c 2
~
1160'C
1170'C~_ _ _ _~
W : Wustite
Mel: Melilite
Kir : Kirschsteinite
30 35 40
2 a {Degreel
Fig. 5.2.16. X-ray diffraction data (eu Ka radiation) for sinter V reduced to
wustite after magnetic separationY
is different from that measured in a laboratory test. From Fig. 5.2.18, the
melting point ofthe glassy silicates present in lump ores taken from the
blast furnace is estimated to be about 600-700°C, which is low in
comparison with values obtained from laboratory tests.
16 " 0
0 p S
1I
0
15 ,; 0
0 t
0
14 .t- o
..c 0
..!'"
13
0
.D 12 .. M M M
iO
8
slag 1
,I
,:.
I
P : p e llets, S : sinter, M : mix
G lassy silicate
of lumpy ore
SiO:
tl7131
L- ~
~-
Ii
Packing
0
~
I
::::JI
Perforated plate
X
2"
c= ~54¢-F
~-
J
~ -Air
Fig. 5.3.1. Apparatus for measuring the pressure drop in the fused packed
bed. 3o
HIGH TEMPERATURE PROPERTIES 447
(a) (b)
Photo 5.3.1. Appearance of fused particles. (a) Pellet (Sr = 0'3); (b) Sinter
(Sr = 0-3).
TABLE 5.3.1
Physical Properties of Samples Prepared for the Pressure Drop Measurement
50000
~I-
II
Fig. 5.3.2. Pressure drop correlations for packed beds having fused and
unfused iron ore.
HIGH TEMPERATURE PROPERTIES 449
l::..P
L
= Ib(_l)(~)(pgU2)
IjJDp Cb 2gc
(5.3.8)
Furthermore, eqn (5.3.8) means that the pressure drop in the packed bed
is governed by the frictional resistance between the total surface of the
particles and the fluid. 28
The resistance coefficient, Ib, of 3·5 corresponds to the friction
coefficient under the turbulent flow of Ergun's equation.
In eqn (5.3.8), variables that change due to fusion are Cb, D p , IjJ andA
However, Dp, IjJ and Cb do not show a large change resulting from fusion
when the degree of shrinkage ranges from 0 to 0'47, and the specific
surface area, Qp' that includes them changes only a little relative to the
degree of shrinkage.
(5.3.9)
Eu 4
II=: Sinter
Pellet I
"
~
0 3 X X
0
"'"
Q)
0 0 0
2 0
u
iu
~
u
Q)
"-
<f)
0
0 0.1 0.2 0.3 0.4 0.5
Degree of shrinkage Sr I-I
Fig. 5.3.3. Effect of the degree of shrinkage on the specific surface area of fused
particles. 30
The reason why the void fraction, Cb' does not change with shrinkage
of the packed bed is that the shrinkage of the bed is due to shrinkage of
the component particles when the degree of shrinkage is up to approxi-
450 BLAST FURNACE PHENOMENA AND MODELLING
20
I 15
x : Sinter
o : Pellet
5
Ergun
Fig. 5.3.4. Relationship between the friction factor and the degree of shrinkage. 30
5.3.2.1. Assumptions
This model was made based on the following assumptions. A
cylindrical packed bed of height Lo and diameter D is packed with
spherical particles of diameter Dp and radius rp. These particles shrink
to 2b in the compression direction and expand to 2a in the cross-section
direction when they are softened and fused (Fig. 5.3.5).
101 Ibl
Fig. 5.3.5. Model of packed bed having (a) unfused and (b) fused particles. 30
The change in the packed bed upon shrinkage and the pressure drop
take place based on the following assumptions:
(5.3.11 )
tiP
1;; =
(ICm )2(CPDp1)(p19cu 2
) (5.3.13)
(5.3.17)
(5.3.18)
mo = I - n (~D~) (5.3.19)
(5.3.20)
TABLE 5.3.2
Relationship between the Fractional Open Area and the Void Fraction of the
Packed Bed Before Shrinkage
Fractional
Run No. Raw material open area, Void fraction, Coefficient
mo(-) eo (-) a (= mole o) (-)
(a) (b)
(c) (d)
Photo 5.3.1. Appearance of cross-section of unfused packed bed (self-fluxed
pellet). (a) mo = 0'32; (b) mo = 0'38: (c) mo = 0'41; (c) mo = 0'45. 30
HIGH TEMPERATURE PROPERTIES 455
m = 1 - (1 - 0.860) - - r (5.3.22)
1 - Sr
Next, the particle diameter ratio, y, is given by eqn (5.3.23) from the
relationship to the degree of shrinkage, S" as shown in Fig. 5.3.6.
y = 1 - 0'25Sr (5.3.23)
Figure 5.3.7 shows the relationship between the fractional open area,
m, calculated with eqn (5.3.22) and the degree of shrinkage. The degree
of shrinkage, S" is 0·58 at a fractional open area 60 = 0'5, for example;
this means that the gas flow through the fused bed stops completely.
TABLE 5.3.3
Fractional Open Area Measured by QTM (se1f-
fluxed pellet, Sr = 0, eo = 0-42)30
10~
- x
f2"E 0.9 o~
o 0
0
II
0.8
0.7 '-------'----'------'-----'---'------!
o 0.1 ~2 0.3 0.4 0.5 Oh
Degree of shrinkage Sr (--I
0.5
E 0.4
oQ)
(;
c 0.3
Q)
"-
o
o 0.2
(5
t 0.1
.g
0.3 0.4 0.5 0.6
DeQree of shrinkage Sr (-I
Fig. 5.3.7. Relationship between the degree of shrinkage and the fractional
open area.
~p
L = em
(I) 2( I
l/>Dp(1 - Sr)
)(p~gcu 2
) (5.3.24)
Conclusion
The flow resistance of gas through the fused packed bed, which is
necessary for the calculation of the gas flow near the cohesive zone in
the blast furnace, has been measured.
HIGH TEMPERATURE PROPERTIES 457
,/
102
10
.,y't
•• 0 • •
.' .~.D
.~;;r-
• 0 •
."
<1»-1 0
,. "e(a
,/
10
, ..
/'(1
'"' N. S'
0
•
0 I Pel"
2 Sell fl"'ed P 0
,k(
n
! 3
101
S""'t!I.
P.'Ie'! 038
6 103 S, .. ••• 019
031
:
0 lO- p.!!..
110 Pe'l~ 0"
112 S·", .. 0 ..
. . 113 PIIII~ 0«
10-
10-' 10 ' 1 10 10'
The flow resistance of a gas through the unfused packed bed can be
calculated with Ergun's equation. It is difficult to apply Ergun's
equation directly to the calculation of the flow resistance through the
fused bed. For practical purposes, however, it becomes possible to use
this equation by putting 1·75 + 22S~4 in place of the internal resistance
coefficient of 1·75 in it.
The flow resistance of gas through the fused packed bed cannot be
explained by the theory that it is caused by the frictional resistance
between the particle surface and the fluid. Instead the pressure drop
takes place due to the compression and expansion of the fluid that flows
between the particles whose clearance has become narrow so as to form
an orifice. In this case, the pressure drop is affected by the fractional
open area of the fused packed bed.
Notation
specific surface area of particle (l/cm)
effusion coefficient of gas (-)
particle diameter (cm)
diameter of tube (cm)
458 BLAST FURNACE PHENOMENA AND MODELLING
Water
Weier
Fig. 5.3.9. Apparatus for the preparation of the softened bed of iron ore.
460 BLAST FURNACE PHENOMENA AND MODELLING
1600 r--------------------------,
/
/
~,,/
1400
------------
1200 " -----
....
----
/
/
/
I
I
/
-
~
~
CI>
a.
800
I
/
I
I
o 5
Ti me
1300 , . . - - - - - - - - - - - - . . . ,
Pellet (PU
u -<>- ms = 1085-224.9 fs + 369.7fs 2
!... rr = 13. 1°
Ul Self fluxed pellet: (S P )
E -- Tms=1I17-96.6fs+192 .6fs 2
..... rr = 5.1°
0>
c:: Sinter : (ST)
'2: -6- Tms = 1140 -153.61s+244.7 fs2
~ 1200 u"=ll.loC
g
-...
o
0>
--~
:::l
0>
ST
Co
E I 100 ...---=--=----
SP
--
0>
0>
c::
c:: PL _0
c::
'g.
III
,~
•
0
LI
105
104
0 .34
0.59
10 I 1.00
in " ~ 113 0 . 34
0. 59
0 ,2 }~Cl 0 1 10
• 119 I. 00
... ,,
CI)
CI)
~~ 0
C'>
Q) 0 .3 .l!.C>t. O 0
• ~ ',o
"'0 ., 0
0.4 ~.
"
X " 0
CI)
0- ... ~
C
.><:
0:::: 0.5 ' ...." 0
.;::
.c.
(f)
I Sr~0D2-1 ,41 T"+96.17T"2-429.6 T*3
0 .0396
0
0.6 (1=
a a 005 0 10 0 15
cf)<
-cC>--6 ~bi>P~ I
..........
0. 1 C).... lIfI
......
..!.. eo"tfl...
....
(f) 0.2 ~ ..
A'lo~
Q)
...
CI)
0.3
' ...~.
0-
°
...
.....,
Q) '!I. . . . .
[II
"'0
~~~ R
~ -
0.4 -
° 1 14 0. 3 1 a
~ 11 6 0 . 60
.,. , ...
.
Q)
.-,
0 102 I. 00
0-
• 11 5 0.3 1
c
.><: 0.5 •.: l~ I ?~g
...
0::::
,.,0."
c :t.t., c»
........... <»
0.1 o t......
,
....
<»
(j;
0.2 ~"
(]
0
Q) "
...
QI ~ o
,...',. ,. , ,
01
QI
0.3 ., ""
"
ZI ....
0
,
" RUN
NO
R eo
0 .4 I"- 0 108 0 . 35 ~. -
Q)
'" 106
103
0. 6 1
1. 00
•
01 0
0
.>t:
c 0.5 ..•• 107
II I
0 . 35
0.6 1
\
\
...
s:-
112 I. 00
Sr>O.02-Q251 T* + 26.69T"'':: - 12 . 1T*3
CI) CT= 0 . 0479
0 .6
0 0.05 0.0 1 0. 15
Dimension less temperature T* ( = (Tem - Tms) / To 1
Fig. 5.3.15. Shrinkage curve obtained by numerical optimization (sinter).3o
==:d.====;= CD Load
@Stainless rod
@ThermocouPle
@) Pressure probe
@water sea I
® Reaction tube
®Sample
@Grid
®Electric furnace
@Gas mixer
TABLE 5.3.4
Characteristics of Sample
I 0 '4
1\1
,
E
(,)
....... 10 '3
rn
Ii>
10 '2
~
>.
"U
>. I 0"
rn
0
()()~<&_~""""IIOOOc
'0
(,)
If)
>
10
0>
----15. . .
-
~
~~.....t) 1200°c
~
10 9
.~
Q)
.....
0
(f) e-e,1 250°C
10 8
0 1.0
P rereduct ion degree fso(-)
Fig. 5.3.17. Effects of prereduction degree and the reduction temperature on
the softening viscosity.33
where Gi is the elastic resistance of the i-th mineral phase. Since the
elastic deformation is too small to be measured in this experiment, the
second term on the right-hand side of eqn (5.3.29) can be neglected and
the following equation is obtained:
dS r
Wi = 17i dt (5.3.30)
Since the total loading force is equal to the sum of the loading forces to
each mineral phase, one obtains
W = l:W
I
. I (5.3.31)
~ 50
60 Wustite ,
,"
§ 40.c. ............~ Hemotite "
'0 30 ~ ~ :\~ ____ _
c: 20 ....-t~J=M:
~ I ~ Calcium - ferr ite Slog
u 0 0 .2 0 .4 0 .6 OS 1.0
Load
G, 7Jn
t ---
Load
Fig. 5.3.19. Rheological model of softening behavior. 33
468 BLAST FURNACE PHENOMENA AND MODELLING
W dSr~
= dt -t,ryi (5.3.32)
On the other hand, eqn (5.3.28) is valid from the results of isothermal
softening tests under load. By combination of eqns (5.3.28) and (5.3.32),
the following is obtained:
(5.3.33)
where
(5.3.34)
As mentioned above, the overall softening viscosity of sinter (ry) and
the amounts of each mineral phase during reduction (XJ are
determined experimentally. By applying these results, the softening
viscosity of each mineral phase can be calculated by solving eqns
(5.3.33) and (5.3.34).
The temperature dependence of the softening viscosities of each
mineral phase is shown in Fig. 5.3.20. These relations are expressed by
eqns (5.3.35)-(5.3.40).
Inl1~e -6-41 + 44 190/T (5.3.35)
In1J~s - 15·85 + 53 540/T (5.3.36)
In1J~lag = -77,50 + 114540/T (5.3.37)
Inl1~ag = -8,82 + 48 760/T (5.3.38)
In1J~ema = -11-45 + 53 220/T (5.3.39)
Inl1~a_f = -17'83 + 55 790/T (5.3.40)
Since some empirical equations are combined in the calculation, the
accuracy of the results might not be so good because of the
accumulation of the individual experimental errors. However, it can be
said that the softening viscosities of mineral phases tend to decrease in
the order: hematite, magnetite, metallic iron, wustite, calcium ferrite,
slag.
(c) Interpretation of the existence of a minimum softening viscosity at a
specific prereduction degree. As shown in Fig. 5.3.17, there exists a
minimum softening viscosity at a specific prereduction degree. This is
explained by the difference in softening viscosity of each mineral phase
as follows.
HIGH TEMPERATURE PROPERTIES 469
Temperature (OC)
900 (\j
E
0
"-
rn
10 15
..,c:
Q)
30 "'C
f:' 10 10
..,
c: 20 rn
0
~ 0
rn
>
10 5
10 0>
-
c:
c:
Q)
0
(/)
1600 60
1400 50 c::
0
1200 40 I/)
o ~
u a.!!..,
!!.., 1000 30 E
0
...
-
Q)
u
:::J
800 20
I/)
...
0
Q) 600 10
0
<.!)
a.
E
Q)
400 0 N
~
"C
E
u
0 -....
200 1.0 0 0>
...J .:6!
0.5
0 0
0 2 3 4
Time (hr)
STeal =
i-
lW dt
o T/
where the overall softening viscosity T/ was calculated by the use of eqns
(5.3.41)
(5.3.33)-(5.3.40).
Figure 5.3.22 shows an example of comparison between the calculated
shrinkage degree and that observed. It has been confirmed that the
shrinkage degree during the reduction process under conditions of
elevated temperature and gas composition change are in good
agreement with the values obtained by integrating the shrinkage rate
base on the softening viscosity with respect to the shrinking time.
These results reveal that the distribution of shrinkage degree in a
blast furnace under conditions of arbitrary distributions of temperature
and gas compositions can be estimated by the use of the softening
viscosity for various ore materials with the help of the mathematical
simulation model. Therefore it is believed that the application of
softening viscosity is quite effective in reflecting the softening properties
with the mathematical blast furnace simulation model.
0.1
0.2
.L 0.3
eli
., 0.4
~
.,
CI
0.5
-0
., o
CI
0 0.6
.><
o
.".r:."
(J)
0.7
o Actual result
0.8
- Calculated result
0.9
1.0
Temperature ( ·C )
1
Properties of ore
/l High.temperature
cohering rapId
[law.temperature
cohering slow
J
melling Iype melting type
Cohesive
layer
Raceway
The cohesive zone formed is located at the lower part of the furnace and
is narrow. The picture on the right shows the cohesive zone formed with
the use of poor quality burden materials, which melt at lower
temperatures and at a lower rate. In this case, a cohesive layer of poor
permeability is formed at low temperatures. As a result, both the layer
thickness and the coke slit length are increased, leading to unstable gas
flow due to increased pressure loss. The formation of the cohesive zone
at a relatively low temperature region, i.e. at the lower part of the
furnace, reduces the volume of the lumpy zone, resulting in diminished
gas utilization rate. Furthermore, the delayed melt-down caused by the
'root' (the portion where the cohesive zone makes contact with the
furnace walls) makes burden descent unstable.
As yet, unified standards for evaluating the high temperature
properties of the burden have not been established. In recent years,
however, a number of testing devices for measuring the high temperature
properties of burden under load have been developed and installed in
blast furnaces for operation control.
The test results of the high temperature properties of burden under
load are usually expressed by the temperature-shrinkage, -pressure loss
and -reduction rate curves as shown in Fig. 5.4.2. The burden having
low shrinkage, low pressure loss and high reduction rate, as obtained by
comparing the curves in Fig. 5.4.2, is usually considered desirable.
Many attempts have so far been made to determine the standard values
for evaluating the high temperature properties by selecting those values
regarded as important for blast furnace operation from these curves. An
example of such standard values is given in Table 5.4.1.
o~ 100
0-
":i 400
.§ '--_--=-~~---I
U
o ""
o'-----"'=-- -";"""'~~---Il 00 -- 0
1500
Temperature [OCI
Fig. 5.4.2. Comparison of high temperature proQerties between acid pellets and
self-fluxing pellets. 36
:!:J
.j::.
o:l
~
...,
TABLE 5.4.1
Criteria for Evaluating High Temperature Properties of Burden
Item Criteria
tT1
Shrinkage and
softening temperature
(1)
(2)
Temperature-shrinkage curve 37 -4Q,44
Semi-softening temperature defined as temperature at 20% shrinkage 43
I
'1:1
::r:
(3) Softening temperature defined as temperature when pressure loss reaches 100 mm Aq42 ~
(4) Softening temperature defined as temperature when shrinkage reaches 50%36
o
~
(5) Shrinkage expressed by temperature at 60% shrinkage43 tT1
Pressure loss (1) Permeability resistance index, K, obtained from permeability resistance equation: 34, 49, 51. 54 ~
tJ.PIL
~
tl
K=
pI - fJ "/1fJ " U 2 - fJ ~
o
K, permeability resistance index (MKS units); p, gas density (kg/m2); /1, gas viscosity tl
tT1
(kg/m" s); U, superficial gas velocity (m/s); {3, gas flow coefficient (-)
(2) Maximum pressure loss value and temperature at that time 36,47 ~
(3) Temperature range from start of softening to maximum pressure 10ss42, 45,46 o
Tempera ture-risel
reduction rate 38,40, 42
Melt-down temperature (1) Temperature at which slag or hot metal starts to melt down 36,4O.42,47-50
(2) Temperature range from start of softening to start of melt_down41.48
Integrated value of (l) KWO(h integrated value of permeability resistance during time from 1000 °C to maximum
pressure loss pressure 10ss46
K woo , mean temperature during above-mentioned time
K1OO , integrated value of permeability resistance during time from 100 mm Aq of pressure
loss to maximum pressure loss
K 1OO ' mean temperature during above-mentioned time
(2) S value :36. 52
~
~~
::J
III "0
III
..
t ~
"0
6PA 1- - - - - - - - - - --..,-
~ / / /\" tTl
~
tTl
rJ]
Temp.-+ (e)
~
Vl
476 BLAST FURNACE PHENOMENA AND MODELLING
1500
I I I
Melting down temp.
Ci
40 .... 1450 10-
35
\,,0 ci.
E
2
~,.p~
~ 0 3 1400
o V
30 " a'
~ 25
~ ~ 1350
c
o
~20
\0
\
1:.3 1250
~ ... ~.
...
Softening temp.
~o ci.
/'
~ ~ 1200
U 15 ~
10
o~
0
..r>n
g'
~
o
1150 V
'"
5 1100
o 0.5 1.0 1.5 2.0 o 0.5 1.0 1.5 2.0 2.5 3.0
MgO content (%) MgO content (%1
Fig. 5.4.3. Effect ofMgO content on the contraction (11 ()() C) and the softening 0
500
/
•
/
/
F.R. /
490
.O~.
o· ,
·l
480
54
I I
Q. 470
_. ,-
• No.1 BF p~ .'~
53 - I- Z
'1 1 '.
o No.2BF 460
<lJ
~ 52 '§
o ] 450
I~~·
~.
• ~
C.R
..~
U 51
+ ~
.~~
o 0 440
r'" ,7
Ve6?'
<lJ
."
Sd 50 - '§
o 49 -
"-
.~ • <lJ 430
U f-e.
.~
.-
~
U ~?~
• 420
,'}l ~
",,_'0
48
.~
410
47
0 10 20 30 40 50 ~~ • No. IBF
1 1
1.6 1.0 0.4
MgOI%1
530
'.1 .I
Unstable
I
Stable
I
_ 510 ~ /' ;:
f ;; :-::
Optimum
~ r--... ;; /~
"
"'.
0
Q) 490 /-
~ ~
,~
]
~"""""r-...
ro. r--
-
470
450
o 10 20 30 40 50 60 70 80 90 100
Blending ratio of porous pellets 1%1
Fig. 5.4.5. Relationship between the blending ratio of porous pellets and fuel
rate. 55
I I
'1-
I I I I
"'"
I I I I
'I'
I I I
Bela.. Improved pellets
_I_Improvement .~.
MgO=1.5% MgO=1.75%
]
c
"' E
~
o ;;;-
20~
10
I ,-. • • ~
I
50
40
~ .- A
]; ~
Qi 0
30
\./ -...- ........
CL
2 20
10
0
~c,~~ 4
5oo,---------------1
2 ~ ~O~,--~--~-----~
2 ~
Q)~
~ =' 4 6 0 1 - - - - - - -.....f - -....._ .......
MOL-----------~
55. 0 .----------~
~ 54.5
.~
c
.Q
0 54.0
/.
.~
=>
~
0 53.5
0'"
U 53.0
\2 1360
'"'"
~.;::
1340
./
•
.
~ /""
_.
1320
if.
0
~.~
'"0 1300 ......... ~.
~
0 1280
Q;
Q.
E
'"
f- 1260
1380 1400 1420
Melt-down temperature lOCI
1.9,------------------,
1.8
50,-------------
>- 40
a
<J
<IJ
~ 30
"
Q.
D
+
.~
20
Vi
X
M
10
O~-~--~~~L-_~ _ _~
1380 1400 1420
Melt-down temperature ITI
-
~
20
/ ,
18
~
"0
iiiQ.
E 16
2
c
.g
(J) 14
[i
/
0
0
E 12
(J
Vi
10
0 0.5 1.0 1.5 2.0 2.5
S-volu81"C.kg/cm 2 1
Fig. 5.4.10. Relationship between S-value and sigma of pig iron temperature. 52
0.15
/.
.. j
.I /
013
~
c
~ 011
8
Vi
0
0
6,
009
/;
Vi
007 •
005 0
II
0.5 1.0 1.5 2.0 2.5
S-',olu81"C.kg/cm'l
(5.5.1)
Uo (m/s)
Range in the blast furnace
4
xlO 00 2 0.5
6~~--~----~~------~
Shrinkage
degree :Sr
4 /0.431
tY.
.
6.t1'
2 .,.#_ • __ ~0.384
......
1 I (P. uol."P )
Fig. 5.5.1. Example of experimental results from the gas permeability test
through the softened materials. 68
I
X 104 xl0 8
10~-----------O~ 5~------------~
8 OSinterB 0Sinter B I
}
4
.6SinterC .6SinterC
6 X Sinter D/x0 N 3 XSinter 0
4 x ~ 2
2 r-
a
,A:8~ /x
~,"oX I
Fig. 5.5.2. Effect of shrinkage degree on the coefficients of gas flow resistance
(K J and K 2 ).68
::I:
TABLE 5.5.1
Characteristics of Sinters used for the Gas Permeability Test 68
5::I:
>-l
tTl
Chemical composition (%) ~
Sample RDI Reducibi/it)f (-) '"tl
tTl
T.Fe FeD CaD SiD 2 AlP3 MgO TiD2 (-3mm%)
Sinter B 56·53 7·64 9·96 6·24 2·02 0·84 0·14 48·2 0·873
Sinter C 55·23 7-18 1(}42 5·99 2·05 0·92 0·14 33-1 0·845
'"tl
Sinter D 56·08 6·88 9·26 5·88 2·30 1·39 0·85 38·1 0·839
I
~
'"tl
aMean reduction degree achieved at 1300°C. tTl
~
tTl
'JJ
""'00
Vl"
486 BLAST FURNACE PHENOMENA AND MODELLING
3.56
1400°C
Tuyere
3.58
3.89
ML=I.O x Rf
Fig. 5.5.3. Effect of softening properties of sinter on the gas flow in blast furnace?O
Q)
Shape of the
0
co ~
+20 cohesive zone
o~
t;~
'"....
Q)
~ Q)
Eo 0
_0
co
'"o ....:::3
-
0>-
co
.-
Q)0
0>-
'" -20
co.Q
0
~co
u·-
1.0 2.0 X 10 4
temperature K
Fig. 5.5.4. Effect of softening properties of sinter on the gas flow resistance in
blast furnace.
1.0.-------------------...,
at high
temperature (-)
_ 0.8
I
~ 0.6
~
'"'"
"t:J
~ 0.4
a
"'c"
0.2
0.55~ 0.60
OL-____~____~______~--~~~--~
1200 1400 2200
] ~ f-----------~------=:O:--___j
:::
~ 0 7
~
.g 0.6
OJ
ijj 6. 0 5
10
OJ
1: ~] 8
OJ Q) Q)
i':o 0N 6
1300
Melt-down temperature lOCI
Ie K-BF, operation datal
Gas temperature
at top
Gas
flow
PI Outside
P,
Cohesive
layer Pressure
at shaft
P:i
Fig.5.5.7. Schematic illustration of (a) gas flow around cohesive zone and (b)
gas temperatures for calculation. 59
HIGH TEMPERATURE PROPERTIES 491
Time Ihrsl
25
No. FR Si
CD 460 40
<2l 490 50
(3) 540 80
E
o
.to 10
.
1:
.Ql
I 5F--=--I
'\
o \~'t.
L-J.----'---...J....{ I I I I
5.6. NOTATION
REFERENCES
1. M. Hatano, T. Miyazaki, T. Shimoda, Y. Iwanaga and T. Kirino, Tetsu-to-
Hagane, 66 (1980), S696.
2. T. Miyazaki, T. Shimoda, Y. Iwanaga, K Yamamoto, I. Shimizu and
T. Kataoka, Tetsu-to-Hagane, 67 (1981), A13.
3. K Hayase, T. Ohshima, H. Fujimori and A Sasaki, Tetsu-to-Hagane. 67
(1981), A17.
4. c. Yoshii, K Ishii and T. Konishi, Tetsu-to-Hagane, 63 (1977), S484.
5. S. Kondo, M. Sugata and T. Sugiyama, Gakushin Seisen 54-Committee,
No. 1348 (1975).
6. Y. Yamaoka, H. Hotta and S. Kajikawa, Tetsu-to-Hagane, 66 (1980),
1850.
7. K Okabe, A Sasaki and H. Kokubu, Gakushin Seisen 54-Committee, No.
1524 (1980).
8. K Narita and M. Maekawa, Tetsu-to-Hagane, 63 (1977), 1443.
9. K Inoue, T. Ikeda, T. Uenaka and M. Kanemoto, Tetsu-to-Hagane, 68
(1982),2441.
10. K Mori, R Hidaka and Y. Kawai, Tetsu-to-Hagane, 66 (1980), 1287.
11. K Narita, M. Maekawa, M. Kitamura and H. Kanayama, Tetsu-to-Hagane,
65 (1979), 368.
12. O. Tsuchiya, K Ohtsuki, T. Sugiyama, M. Onoda and I. Fujita, Tetsu-to-
Hagane, 66 (1980), 1297.
13. K Narita, M. Maekawa, M. Deguchi and T. Saito, Tetsu-to-Hagane, 66
(1980), 326.
14. K Narita, M. Maekawa, I. Shigaki and Y. Seki, Tetsu-to-Hagane, 63 (1977),
1623.
15. 0. Tsuchiya, K Sugiyama, M. Onoda and I. Fujita, Tetsu-to-Hagane, 66
(1980), 1840.
16. K Narita, M. Maekawa and H. Kanayama, Tetsu-to-Hagane, 66 (1980),
1860.
HIGH TEMPERATURE PROPERTIES 495
45. Kimitsu Works, Nippon Steel Corp., Bulletin 58-21 (1981), Ironmaking
Committee, Organization of the Joint Research, ISU.
46. Fukuyama Works, Nippon Kokan KK, Bulletin 58-19 (1981), Ironmaking
Committee, Organization of the Joint Research, ISU.
47. Nagoya Works, Nippon Steel Corp., Bulletin 58-17 (1981), Ironmaking
Committee, Organization of the Joint Research, ISU.
48. Kashima Works and Central Research Lab., Sumitomo Metal Industries
Ltd, Bulletin 58-23 (1981), Ironmaking Committee, Organization of the
Joint Research, ISU.
49. K Yasumoto, R Yamashita and K Yamamoto, Tetsu-to-Hagane. 66 (1980),
S43.
50. K Shimizu, T. Kataoka, A Kawai, K Yasumoto and K Yamamoto, Tetsu-
to-Hagane. 66 (1980), S701.
51. M. Hatano, T. Shinoda, Y. Iwanaga and T. Kirino, Tetsu-to-Hagane. 66
(1980), S699.
52. Y. Abe, Y. Umezu, K Yamaguchi, K Iida and M. Saito, Bulletin 54-1551
(1981), 54th Committee (Ironmaking), Japan Society for the Promotion of
Science, Tokyo.
53. T. Miyazaki, T. Shimada, Y. Iwanaga, K Yamamoto, I. Shimizu and
T. Kataoka, Tetsu-to-Hagane. 67 (1981), AB.
54. T. Narita, M. Maekawa, I. Shigaki and Y. Seki, Bulletin 54-1440 (1978), 54th
Committee (Ironmaking), Japan Society for the Promotion of Science,
Tokyo.
55. K Taguchi, T. Sato and S. Fukihara, Ironmaking Proc.• AIME, 39 (1980),
363.
56. K Taguchi, T. Uenaka, T. Sato and M. Maekawa, Presentation of Technical
Paper, Vol. 1 (1979), 155, lIS I, Committee on Technology, Rio de Janeiro,
Brazil.
57. M. Hatano, K Kurita and K Akamatsu, Bulletin 54-1428 (1977), 54th
Committee (Ironmaking), Japan Society for the Promotion of Science,
Tokyo.
58. M. Hatano, H. Yamaoka and C. Yamagata, Tetsu-to-Hagane. 62 (1976),
S391.
59. Y. Togino, M. Sugata, K Yamaguchi, M. Nakamura and I. Abe, Bulletin 54-
1456, 54th Committee (Ironmaking), Japan Society for the Promotion of
Science, Tokyo.
60. Y. Togino, M. Sugata and K Yamaguchi, Tetsu-to-Hagane. 65 (1979),
S51.
61. H. Itaya, M. Araya, T. Funakoshi, A Kani and S. Kiyohara, Tetsu-to-
Hagane. 65 (1979), S50.
62. K Yasuda, H. Kimura, N. Nakano and N. Morishita, Tetsu-to-Hagane. 64
(1978), S533.
63. T. Yamamoto, H. Kanoshima, T. Takahashi, I. Ogata and Y. Hayashi,
Tetsu-to-Hagane. 67 (1981), S74.
64. S. Waguri, N. Morishita, A Kodai, T. Kajiwara and A Kawasaki, Tetsu-to-
Hagane, 66 (1980), S686.
65. M. Kase, M. Sugata, K Yamaguchi and H. Nakagome, Tetsu-to-Hagane. 66
(1980), S685.
HIGH TEMPERATURE PROPERTIES 497
The Raceway
The first quantitative study of the raceway formed at the blast furnace
tuyere was conducted by Wagstaff and co-workers l in the 1950s.
Mterwards various measurements and blast furnace observations were
carried out by use of cold and hot models and experimental and
commercial blast furnaces.
498
THE RACEWAY 499
I
E12 (S1 C - Raceway
/;:---I ___ boundary
/' / '" 52
/ I S 13 E13',
/ S12/
\I Ell B I\ D
.......- 53'
I
El
_ *p J\
IE10~Sll _ E3 -
" ~ 0 '",- __ - -'57 54 Tuyere
\~~S6
\E7~
55
>----
E \, E2 E5
\'" E6 E4
---
Fig. 6.1.1. Coke movement in the model raceway.
smaller the coke size and the larger the blast volume, the higher the coke
velocity. Table 6.1.1 shows the relationship between the number of coke
particles that flow into the raceway and the blast volume. The quantity
of coke flowing in is far larger than the quantity of coke burned,
calculated from the blast volume. Further, bright and dark coke
particles exist, as shown in Table 6.1.1. Therefore it is assumed that a
large amount of coke circulates in the raceway.
TABLE 6.1.1
Number of Coke Particles Flowing into the Raceway
Particles measured
(number!charge) Particles Proportion
Blast flowing in of dark
(Nm3/min) Bright Dark Total (number/s) particles (%)
that the falling of unmelted ore into the raceway and changes in the
brightness of the raceway agreed with the charging interval of the blast
furnace burden and that the cohesive zone affects the raceway.
From experimental studies, such as model experiments, it has been
considered that the raceway expands as the particle size of coke
decreases. Nakamura et at. 7 reported, however, that the raceway shrank
horizontally when very small coke powder was generated in the raceway
due to a decrease in coke strength and for other reasons, and
accumulated near the raceway. It has been confirmed in actual blast
furnace operations, as well as in experiments, that in such cases the
amount of gas flowing near the furnace wall increases.
In Fig. 6.1.4 the distribution of coke powder at the tuyere nose
obtained during operation with formed coke is compared with that
obtained during ordinary operation. The reason why the amount of gas
flowing near the furnace wall increases, as shown in Fig. 6.1.5, seems to
be that the accumulation of coke powder in the raceway reduces the
permeability in the coke bed in this area and, at the same time, makes it
502 BLAST FURNACE PHENOMENA AND MODELLING
difficult for coke to move as a result of the force of the flowing gas. As a
consequence, a wall comprised of fine coke bed is formed near the
tuyere nose and the refraction point of the gas flow changes.
2200 2200
~
E
2
~ 1800 1800
0
u
1600 0 1600
0.5 1.0 1.5 2.0 2.5 0 0.5 1.0 1.5 2.5
12 12
10 10
Ordinary coke
°0-L---~0~.5--~1~.0--~1~.5~~2~.0~~2~.5 o oL---~0'-::.5--~I"-:.0,-----:I,..,.5~~2::':.0~----:02.5
Distance from furnace wall 1m) Distance from furnace wall 1m)
500
400
2 300
i" 500
-5 400
~ 300
E 200
.22 100
~ 300
Q)
u
200
,~ 100
~ 700
600
500
Fig. 6.1.5. Blast furnace shaft temperature during the experiment with formed
coke.
THE RACEWAY 503
2 2000
<1l
--..0__ Pitch coke
Carbon brick
<1l c Ordinary coke ........................ 0 Pellet coke
.2 8 1800 o 0....0' ..........
2C Weak coke Formed coke --_,_ Charcoal
~~
~ ~ 1600
;~
<1l <1l
o . . . 0 ........
--
~£ 1400
Io
0.1 0.2 0.5 1.0 2.0 5.0 10.0
Gasification velocity II/hrl
IT uyere level I
800 800
~
.
0-
600
01
" I
600 ~
0-
<{
E
~
~
0 400
• 400
..
~
"-
"~
200~
E
~
., 200
a
0
0 0
0 0.4 0.8
Distance from the furnoce wall Iml
16 40
]
bl /C"o---
12 30 ~
"Oi>-l • • 11 I) • -£
~
1 0.8 boundary of
Ihe raceway
20 0
U
~
0 0.4 __ 6_
Hz
10 6
.D
---- ~
U
0
:E CO 2
CD 0
'0;
I
side, since the heavy oil burns at the tuyere nose and consumes oxygen,
which brings about the result shown in Fig. 6.1.8.
The humidity and oxygen concentration of the blast affect the
composition concentration of gases and temperature distribution near
the raceway. According to the results of measurement in an experimental
blast furnace by Kodama et at} as shown in Fig. 6.1.9, the temperature
near the raceway decreases with increasing moisture in the blast and, at
the same time, the lines of equal CO2 content expand as the oxidation
zone expands. In an experiment with a bench-scale raceway furnace by
Nakamura et at,,? it was recognized that the raceway volume increases
markedly, as shown in Fig. 6.1.10, due to an increase in the moisture in
the blast. Although there are many unclear points in this mechanism, it
seems that it has some relationship to the above-mentioned expansion
of the oxidation zone.
Measurement in the raceway is difficult because of temperatures
above 2000°C. Therefore, to understand the raceway zone, there has so
THE RACEWAY 505
Tuyere level
800 800
V, : 903 INm1 m..1
~ 01
02: 3 !Nm 3 mini
...." 600 0;1: 57! I mini
0..
~
E 400 400 .~
o
iQ. ;:
~ 200
'-- .• -_.-x
200 i
(l
o O "L-~-~-~-~-~~ o
o
0.4 0.8 12 1.6 2.0 2.4
Di.lonce from the furnoce wall !ml
40
bl
]
~ 12 30 ~
'>" :£
~bOUndarY
E
~'" 08 of 20
0U
'>"
0
.0 04 ,,-
r~-~~~~Y
H! 10 c5
0 U
.<:
'"
'iii 0
J: CO 2
Fig.6.1.8. Effect offuel oil injection on the combustion in front of the tuyere.
Fig. 6.1.9. Effect of humidity and oxygen in blast on state of combustion zone
(blast temperature 800°C).
506 BLAST FURNACE PHENOMENA AND MODELLING
5000
1; 4000
~
>'"
"5 3000
o>
>-
o
~
B
o
2000
~
50 100
Humidity Ig/Nm 3 1
far been no other means than to put together the results of a range of
examinations and a series of assumptions to produce a general concept
model of the raceway.
In recent years, however, progress has been made in high temperature
measurement techniques, as mentioned in this section, and attempts
have been made to measure directly the raceway in a large blast furnace
in operation. It will not be long before the phenomena in the raceway
are clarified.
----------
Confi gurati on and fractional
migration of carbon transferred
and ~---r
I ",,' :
Boudouard reaction I
~~
"
,I
:MO+ C-M+CO ~
Direct reduction *"""""---------<
I
Carburization
Hearth ~(10.0"lo)
- --
can be theoretically represented by the following equations which were
applied to the blast furnace system: J3- 15
divF = 0 (6.2.2)
- = -U; + I~IF
gradP I)F (6.2.3)
where F is the molar flux vector of the gas, P is the gas pressure, and
li,f~are Ergun's coefficients.
THE RACEWAY 509
(a) (b)
l5
-a::
I
::: 1-0
0·0 '---_............
_---1
Figure 6.2.2 represents the gas streamlines and the isobars obtained
by the computation for the present experimental system, considering a
raceway as a loosely packed bed. Fairly good agreement between the
predicted and the experimental streamlines verifies the validity of the
numerical treatment to determine the gas flow patterns around a
raceway.
Near the tuyere combustion zone, however, the molten materials pass
down countercurrently to gas flow. Szekely and Kajiwara 16 attempted to
elucidate the liquid flow patterns observed by the use of a two-
dimensional cold model having a tuyere and in terms of a continuum
theory of approximation. The set of equations used by Szekely16 were
basically analogous to the gas flow equations (6.2.2) and (6.2.3) except
that}; became zero and the gravity force was taken into account.
In this work, the experiment was conducted with a half-sectioned
cylindrical cold model (248 mm in diameter by 700 mm in length) made
of transparent plastic resin. Nine tuyeres of8 mm I.D. were installed to
510 BLAST FURNACE PHENOMENA AND MODELLING
2.1 1.8
"I
e:. 1.4 ~ 1.2
N
!J i-d-,=.. .,.O..,.,.OO2,.,-6m--+=--i
Q,=O.OlOm'/s
0.7 0.6 Q, =5.2Bx 1O-6 m'/s
- Calculated
• Observed
0.0 L....:.L.-:-'--'--.I..I...:--.....J
0.0 0.2 0.4 0.6 0.8 1.0
r/R I-I r/R I-I
Fig. 6.2.3. Streamlines and the flow rate patterns of liquid in a trickling bed:
(a) calculated streamlines ofliquid; (b) calculated and observed distribution of
liquid flow rate.
THE RACEWAY 511
radius (m)
4 3 2 0
to <D
0 ~ N
6
~ 0 0 0 0
,!!"
u
~
i
I
5
.#
I
~ 4
E
31:
Cl
.c;;
,I;
2
o·T _---.U.~
C·N ~---------~o
hatched part in Fig. 6.2.4. In this work, the numerical value for ~ is
assumed to be 0·25.
where kfi is the mass transfer coefficient, a is specific surface area, TJi is
the effectiveness factor of catalytic reaction, k mi is the chemical rate
constant, and Pbc is the bulk density.
The mass transfer coefficient can be expressed as
(6.2.12)
The mass balance for the total gas over the differential element
becomes
I
5
I
5
I I
3 4
(6.2.21)
where C e and cg are the specific heats of coke and gas, Te and Tg are the
temperatures of coke and gas, - flHi is the heat of reaction, and hge is the
heat transfer coefficient between gas and solid particles.
From eqns (6.2.18) and (6.2.21), the following is derived:
Iri + ceTe I I
5 3 4
= Rt +
i i i
dTg/dx [CgTg Rt(-flH;)
=I =I =I
(6.2.27)
i =I
40
36 Tf =2526 K
Each key: Observed
32 : Calculated CO
28
~
~ 24
2773
g 20
)( 16
>-
12
1773
8
4 1273
00 1 .6
Fig. 6.2.6. Variations of gas composition and gas temperature in the axial
direction of the tuyere zone; plotted data were observed by Inatani et al.
(1973).
518 BLAST FURNACE PHENOMENA AND MODELLING
40
36 TI =2626 K
- : wo2 =0.02 ~,
32 ---: W02 =0
28
oe. 24
2773
g 20
" 16
>= 01
r
12
1773
8
4 HZ 1273
---
DO 0.4 1.6
TI =2526 K
CO
36
32 , .-
.- .-
28 ,
I
/
I
~ 24 I
I 2773
g 20 I
I
1""', . . . , ......
" 16
......
... ~g 2273 ::
~-
12
'"
r-
1773
8
HZ
4 1273
-_.:-:::_====:
0.4 1.2 1.6
Fig. 6.2.8. Variations of gas composition and gas temperature in the axial
direction of the tuyere zone at high temperature and high humidity blowing
operation.
4.0r------------------------,
1: Base
2: w02=O.02
13.0 3: Wst =389/N
u
Ol
.0 T =1373 K
ME
::::. 2.0
u
o
E
rn
~ 1.0
5.0r-----------------------~
,...... 4.0
0·020 m
u
<52.0
E
CJl
-'"
1 •0
1 .6
x (m)
Fig. 6.2.10. Effect of coke diameter on the variation of coke consumption in the
axial direction of the tuyere zone.
(a) (b)
Photo 6.2.1. Time lines of coke tracer in the charged stock of dry ice particles.
(a) After 2 min; (b) after 8 min.
Note
P : static pressure
f : Interaction force between
gas and coke
V:veloclty
9 : gravitational acceleration
Tuyere P : density
fI. : vlsoosity
Subscript
9 : gas
wall c : coke
wall
Fig. 6.2.11. Relationship of forces between gas and coke in the raceway
model.
522 BLAST FURNACE PHENOMENA AND MODELLING
TABLE 6.2.1
Assumptions for the Raceway Model
- -
Equation of motion Viscous fluid Pressure drop in packed
column for gas:
(V g. grad)V g = 0, I1g =0
Coke density
k
-
Stagnant coke:
Vc =0
Pbc= - 2
PclV cl
Pbc <Pbcmax
Raceway boundary /!;+ a!;;;;'/c I!; + a!; </c
k, density parameter; Pc, bulk density;!c' critical interaction force; a, anisotropic
parameter.
- -
(Vc·V)Vc - V2Vc - 1
= -f.lc"'" --f +g
- for coke (6.2.29)
Pbc Pbc
The last term in eqn (6.2.28) describes the interaction force which will be
mentioned later. This term has the opposite sign to the interaction force
--
term in eqn (6.2.29).
(bj Equations of continuity. These are given by
V . (epgVg) = 0 for gas (6.2.30)
V· (PbcVc) = 0 for coke (6.2.31)
THE RACEWAY 523
The following relationship exists between the void ratio sin eqn (6.2.30)
and coke density Pbc in eqn (6.2.31):
(6.2.32)
where Pc is the apparent density ofthe coke. Coke density Pbc is inversely
proportional to the dynamic energy as mentioned later.
(c) Equation for interaction force between gas and coke. This is a
quadratic equation based on the velocity difference between gas and
coke by analogy with the pressure loss equation of a packed
--
column:
-=
f ----
a(Vc-Vg)+b(Vc-Vg) 'IVc-Vgl (6.2.33)
Coefficients in this equation are as follows, after Ergun: 26
r--------
0.4 , - - - - - - - - - - - - - - - - ,
-
'" 0.3
...c
.Q Observed
E 0.2 Calculated
g>
:;<
u
~ 0.1
2 4 6 8 10 12
1/IParticie velocityl' (sec/ml' xl 0- 3
--
To avoid the difficulties in solving fundamental equations, the stream
function vector \if and the vorticity vector ill are defined as follows:
pEV = ~
V X IJI (6.2.35)
Vxv =(0 ~ (6.2.36)
where
P
p = Pg,
= Pbc,
E
E
= e,
= 1,
-- --
V = Vg
V = Vc
for gas
for coke
These are used in place of the velocity and pressure in the equations of
momentum and continuity. By use of this stream function, the equation
of continuity is incidentally satisfied.
-- -
THE RACEWAY 525
- -
In accordance with vector analysis
(V . V) . V), eqn (6.2.28) becomes
1 -2 - . - _ I flg 2- 1-
(! VV 2 = V X (V X V) +
°
(:J-
It is usual to perform the curl operation on both sides of eqn (6.2.37) to
eliminate P, and VPg = is assumed, to obtain the following equation:
{I
V X e(V X 'If) X ill
~ ~} + {I ~~} X V P +
P~ (V X 'If) X ill g flg V ill
2 ~
For coke, eqn (6.2.29) can be transformed in the same manner as for
gas:
{~(V X 9) X w} X VPc + fl cV W
-
V X I(V X 9) X wJ + 2
Pc
The first and the second terms in eqns (6.2.39) and (6.2.40) represent the
inertia forces. The third and the fourth terms respectively deal with the
viscous effect and the interaction force between gas and coke.
From eqns (6.2.35) and (6.2.36), (;j and 9 are related to each other
°
under the conditions V . 9 = and V (ljpE) = 0, as follows:
1 ~
- V . (V· 'If) = -ill for gas (6.2.41)
PgG
1 ~ ~
- V . (V . 'If) = -ill for coke (6.2.42)
Pc
The distributions of (;j and 9 for gas and coke are numerically solved
from eqns (6.2.39), (6.2.41) and eqns (6.2.40), (6.2.42) by a finite difference
method.
526 BLAST FURNACE PHENOMENA AND MODELLING
o (6.2.43)
Exit of gas
\jf, \jf,
= =0
= or + br 2
_.a.
(tJ (Symmetric axis)
(() = 0 (Symmetric plane)
(Common for gas and coke)
Entrance of gas ~
L-...yI" 3W ,,_= \lfr = (OK = 0
(Common for --
P NP
~:
gas and coke)
---\jf-,=\jf-,=-0- ....
r
Fig. 6.2.13. Boundary conditions of the raceway model (coefficients gJ, gz, a, b).
THE RACEWAY 527
the symmetric axis or the symmetric plane. The stream function of gas
has the same value on both of the lines (lJIg = 0). The gas flows uniformly
into the furnace through the tuyere and then flows upwards. On the
other hand, the stream function of coke has the same value (lJIe = 0)
everywhere on the boundary.
The calculation of the vorticity OJ at the boundaries is carried out
using the implicit method by use of coefficientsg 1 andg2 or a and b that
depend on the stream function, the density and the mesh distance near
the boundary.27
TABLE 6.2.2
Calculation Conditions for the Cold Model
20 - - Calculated
----- Observed
- - Calculat~d
E
u
-<=
(J)
CI)
I
10 20 30
Distance from the wall km)
Ibl 0.75 ¢ Particle diameter
On the other hand, the ratio of the upward force by the gas and the
downward force by the load becomes larger as the particle size becomes
smaller. Therefore the raceway grows relatively upwards in order to
satisfy the balance of the forces.
In the actual calculation process, the above-mentioned anisotropic
parameter was assumed to be 2 and 1 for the small and large particles,
respectively, and this assumption resulted in good agreement with the
experimental results shown in Fig. 6.2.14.
(b) Velocity distribution of coke particles in the raceway. Figure 6.2.15
shows the rotating velocity of the particles, where their diameters are
- - Calculated
- - - Observed
20
18.1 em/sec
~\
.8
E
~ 25.0
".-- - . --=-::..-::-- . .
L
. . ....... ,
/;e (
.CJJ /
w 10
I .~:-.
, \ '--..:. ---.-=,-' -)
',S;;:;:>__ \_ - --- --
Raceway boundary
oL-________L -______ ~L__ _ _ _ _ _~
o 10 20 30
Distance from the wall Icml
101 2.5 ¢ Particle diameter
20
E
u
~ 10
I
Raceway boundary
°0~--------lLO--------~20--------~30
Distance from the wall Icml
Ibl 0.751> Particle diameter
30.-----------------------------,
0.45kg/cm 2 G - - Calculated
- - - Observed
20
L
.(J)
Q)
I 10
OL-__~~____-L___U~~----~~
o 10 20
Distance from the wall Icml
101 2.5 ¢ Particle diameter
38 F=======-----i
Eu
;; 20
.(J)
Q)
I
0.10 0.34
Nm 3 /lsec.ml
20 40 60 78
Distance from the wall !eml
2.51; Particle diameter
2 0 , - - - - - - - - - - - - - - - - -________-,
Raceway boundary
0
0 10 20 30
Distance from the wall !eml
101 2.51> Particle diameter
20 ~ ---- ,
Eu
~ 10 ".
".
// /~": I
I
I
-------,
" /
. . . .<? ---_ . . /
I ".
Raceway boundary
0
0 10 20 30
Distance from the wall !eml
Ibl 0751> Particle diameter
V {&Pg-V tJ + Sc
f.1 V-",j g ? j:
= -R j (6.2.45)
Unit N, N N,
weight
----
l..- 0,
"
0, 0,
CO,
CO,
CO
CO
In the tuyere In the raceway In the packed bed
Fig. 6.2.19. Change in the unit weight of gas from the tuyere to the packed
bed.
Since the descent rate of coke is slow when compared with gas, the
temperature of coke was considered to be approximately the same as
that of gas.
TABLE 6.2.3
Calculation Conditions for the Hot Model
~------------------~----------~1800
0.6
1600 ~
u
o
c: 0.5
.2
1400 ~
-
+- _ _--1
u
...0 0.4 .2
E!
...
0
1200 ~
(5 0.3 E
Q)
E +-
Ul
1000
Ul
0
0> 0.2 o
0>
800
0.1
0
distance from the wall (m)
Fig. 6.2.20. Molar fraction and temperature distribution on the tuyere axis.
2.5
25.0 18.4 11.9 7.8 3.7 kg/rod' sec
2.0
°0L-------~I~.0--------~2~.0~------~3~.O
distance from the wall (m)
Fig. 6.2.21. Streamlines of gas simulated for the experimental blast furnace.
536 BLAST FURNACE PHENOMENA AND MODELLING
1.0.
E
.c
! 0..5b~::::=~
0.0. 0.5 1.0. I.
distance from the wall (m)
a C02 gas molar fraction
1.0.
E
~
0..5
'"
'"
.c
large and gas penetrates deeply into the center under the influence of the
jet from the tuyere. However, this gas flow effect is limited to the
periphery of the raceway.
Figure 6.2.25 shows the temperature distribution and carbon
consumption distribution for small coke particles compared with the
base operation shown in Fig. 6.2.23. For small coke particles, the regions
of maximum temperature and maximum coke consumption come near
to the tuyere nose because of the high carbon reaction rate.
1.0
E
....
.s::
Ol
~ 0.5
1--_--"
1190
o~~~~~ ____~~____-.~__~
a 0.5 1.0 1.5
distance from the wall (m)
a. tempera ture
1.0
.s::
.~ 0.5
Q)
.s::
O~ ____~~____-.~____-.~__~
a 0.5 1.0 1.5
distance from the wall (m)
b. coke consumption
Fig. 6.2.23. Temperature and coke consumption distribution simulated for the
experimental blast furnace.
538 BLAST FURNACE PHENOMENA AND MODELLING
2.0
1.5
---- 19. 5 ~
O~ ______ ~~ ______ ~~ ______ ~
Fig. 6.2.24. Effect of particle diameter on the raceway profile and gas
streamlines.
becomes closer to the tuyere compared with the case in which pulverized
coal is not injected as shown in Fig. 6.2.23. This means that the reaction
rate of pulverized coal is fairly rapid.
Figure 6.2.28 shows gas streamlines and the boundary of the raceway
with and without pulverized coal injection. When pulverized coal is
injected, a high temperature region enclosing the tuyere appears. This
increases the gas volume and hence gas velocity in front of the tuyere.
Pressure loss at the raceway boundary on the tuyere axis becomes high.
This disturbs the straight flow of the blast and the streamlines bend
dp = 10.5mm
1.0
E
....
.c 0.5
C>
Q.I
.c
1220
0
0 0.5 1.0 1.5
distance from the wall(m)
a. temperature distribution
1.0 dp =10.5 mm
E
....
.c
C> 0.5
Q.I
.c
0
0 0.5 1.0 1.5
distance from the wall (m)
b. coke consumption distribution
Fig. 6.2.25. Effect of coke particle diameter on the temperature distribution and
coke consumption distribution.
540 BLAST FURNACE PHENOMENA AND MODELLING
1.0
OL-----~----~~----~
o 0.5 1.0 1.5
distance from the wall (m)
o. temperature distribution
1.0
-- .............. ,
- ......
-
E
\ ,
I )"/nf. sec
,------
~ 0.5
/
Q)
.c. """"----- /"
....
.c.
.~
QI
.c.
O~ __ ~ ____ ~ __________L -_ _ _ _ ~
o 0.5 1.0
distance from the wall (m)
mark
raceway boundary
OL-________- L_ _ _ _ _ _ _ _ _ _~L-~--~--~
o 2 3
distance from the wall (m)
Fig. 6.2.28. Effect of pulverized coal injection on the raceway profile and gas
streamlines.
542 BLAST FURNACE PHENOMENA AND MODELLING
1600
0.5 u
c::
0 1400 ~
....u
-c
....
.... 0
c
1200
1000
0
E
800
0.1
0
0 1.5
distance from the wall (m)
Fig. 6.2.29. Molar fraction and temperature distribution on the tuyere axis.
6.3. NOTATION
REFERENCES
546
THE LOWER REGION OF THE BLAST FURNACE 547
taking place, the structure of each part of the lower region, the
distribution of mass and heat, and the interrelations between them are
clarified, the chemistry of metal and slag could serve as a measure of
in-furnace conditions, i.e. operational conditions.
SOFTENING ZONE
MELTING ZONE
/~
K, No
SiO
Z
0
5: 3: 3: N
~ 0 (')
Q ;:;
VJ "-
W
(') <{ Z "-
::; K, No (') S
8 0
;lsiol
C>'
VJ Mg 0
so
I S
Si
!combustionl
tuyere
~rCDkeoshb level
SLAG LAYER
transfer of Si, S, Mn, Fe ~
/
IRON LAYER
Fig. 7.1.1. Schematic diagram of the lower region and the corresponding
reactions.
7.1.1. Introduction
A part of the Si02 in the burden is reduced to metal in the lower region of
the blast furnace. For a long time Si content in hot metal has been used
548 BLAST FURNACE PHENOMENA AND MODELLING
-10.0
5i02
-15.0
-------.
- - - - - _ _ sot
5.0 60
liT X 10' IK-l)
lBF IV
..,.
~
x
0.5
: .6 0 No 3
No 2
E
g
o
u
o
."§
o
-05
-------.;
Slog I
------1
_~e~~~)
0.5 I0 0.5 0 02 0.4
01 bl
Fig. 7.1.4. Profiles of (a) temperature and (b) silicon content in metal around
tuyere zone of dissected blast furnace. 2o
18
I
T2
if) K'
c
A'
E 6
y5
o CaOS~_I-- _ _ _ _-+:----1
E
36-64 Y
'0 4 ~ 45-55 --+-1-1---'-••- -
x
if>
A?~~~~~:::::t~Y-
2
~~KKK::;.co-K /~
C
Fig. 7.1.5. Relationship between silica reduction rate reported in the literature
and the ratio of interface area at 1600°C. 7
7.0
6.0
~ 5.0
<1>
(\ 4.0
u
o 2.0
.~
Vi
3.0
• 0 lumpy zone
Softening and melting zone
.6. Dropping zone labove luyere)
... lin front of tuyerel
1.0 0 {below tuyereJ
~0~0-8~00~90LO~I~OO~O~II~OO-I~20~O~13-00~1~40~O~I~~O-16LOO-l~70-0~18LOO~1900
Temperature lOCI
• 1500"C, CO •= I aIm •
-001
~
Q)
8
'0 Weighl
~ -0.02
OJ~ = 053449
~
o
u ==}
-"'2' M
~ -0.03
1700"C, CO = I aIm
-0.04
2 4 6 8 10 12 14 16
Time 1m in)
As to another source of SiO, the reaction between slag and coke, the
kinetics of SiO generation by the following reaction between slag and
graphite have been investigated: 25
Si0 2(1) + C(gr) = SiO(g) + CO(g) (7.1.17)
The overall rate of the forward reaction of (7.1.17), R SiO (kgmol!s), is
given by the following equation:
R SiO = (W,/MSi02 ) (d[%Si02]1dt) = ksioAs-gAsio2 (7.1.18)
where As _ g and k SiO denote the slag-graphite interfacial area and the
rate constant for the forward reaction, respectively.
The values of kSiO reported in the literature 12,25.26 have been plotted
against the reciprocal temperature in Fig. 7.1.8 and significant scatter is
evident. The correlation line between log k SiO and 1/T obtained by the
authors has a bending point around 1700 DC; at lower temperatures this
relationship can be expressed by the following equation:
k SiO = 9·0 X 104exp( - 86 OOO(RT) (kgmol!m2's'atm) (7.1.19)
558 BLAST FURNACE PHENOMENA AND MODELLING
.
-4.0 9
\\ \\ ~ 43 35 17 5 CQ,Ar 9
41 35 18 6 CO 9
\~
\ \. 6• 4l
A In
35 18
Ar atmospilere
6 CO
-4.5
.'. \
... \ "6 chemIcal anolYSIS
"'~~
~
-5.0
NE
u
~.
0 o • b.
.5 -5.5 o .. i 0
.s
Q)
A~~.
~.GI.·~I
-6.0
" ~bl'~
-6.5
w E R
dl~c::'
OO~
a) - 60 -70 16)
6)
fl~~el
b) 93
cI 07. 70 18) \
d) 5 70 In
-7.0 0) 5 126 171
'11 17) ~gl
5 130
g) 22 180 16)
h) 025,1.2 90,180 19)
-7.5
4A 4.6 4~ ~O 52 5A 5~ 5~
liT X 10' IK-II
CO 1 aIm at 1700"C for 10 min CO 1 aIm of 1700"C for 10 min J CO 101m ot 1700"C for 5 min
Graphite
Graphite •
10 39 SiC powder 10 39 SiC pOINder
41 CaO-39 5,0 2 -20 A1 2 0 3 -51ag 41 CoO-39 5,0 2 -20 A1 2 0 3 -510g 39 CoO-40 5,0 2 -20 AI 20 3
Conleel areo 0.5 crr: z Contact area 1.3 cm 2 Contact orea 6.5 cm 2
01 bl cI
Fig. 7.1.9. Schematic representation of the state of contact of slag droplet with
graphite.
Time (min)
10 20 30
50.0
.-.J
~
I• 0 1700'C
1750'C
I
0
a
U 0 _ _ 0 _ _0 - - - - 0
40.0
~
r5Vi ' \ Sweo,"," we";'"
30.0 •
~no
?J2 l /
20.0 _ _ _ _' - ,_o_~_o_~
/ 1
10 20 30
Time {min)
changes of slag components with time when a slag droplet was held on
the graphite surface. At the instant when the state of wetting shifted to
spreading wetting, the Si0 2 content started to decrease quite rapidly by
SiO generation, and an abrupt change of slag composition resulted.
Figure 7.1.11 shows the effect of temperature on the initiation of
spreading wetting. In these particular conditions, there seems to be a
critical temperature between 1700°C and l750°C, above which
spreading takes place in a short time.
/
E
u 042 35 18 5
J.
o
~ 4
U
o
8 3
U
£,
2
=-
o
1650 1700 1750
Temp I'CI
Fig. 7.1.11. Effects of temperature and slag composition on the contact area
with graphite.
•
I
7 t
/
/V
6
]
o 4 1"1
"
Q)
co
I [~-/0
1750·C 1 aIm
v
(00% S,OI% AlzOJ% MgO% so,;,
~
o o 41 39 20 - -
U 2 • 39 40 20 - 08 -
o 41 355 18 55 -
• 32 41 17 9 0.9
~ . .!.
I
o
o 5 10 15
Time (min)
7.2.1. Manganese
The reaction of Mn in the blast furnace is given as follows:
MnO(l) + C = Mn + CO (7.2.1)
logK = - 11 600fT + 7·68 (7.2.2)
THE LOWER REGION OF THE BLAST FURNACE 563
7.2.2. Titanium
In ordinary blast furnace operations in Japan, Ti is included in the
burden at about 2 kgTiit-hot metal, its major sources being ore and
coke.
At blast furnace hearth conditions, Ti is known to be amphoteric, and
the ratio Ti3+ ITi 4 + varies with temperature, Pco and the basicity of the
slag. 29
Although levels of up to 10% of the oxide in blast furnace slag
improve its viscosity, the fluidity of hot metal decreases with increase in
Ti content, and hot metal becomes almost non-fluid at a titanium level
of 0·8% at 1500 0c. 30 This is mainly attributed to the strong interaction of
Ti with Nand C:
Ti + C(gr) = TiC(s) -31300 + l4·llT (7.2.5)
Ti + V2N2 = TiN(s) -66900 + 32·9lT (7.2.6)
Nitride and carbide formation have quite large temperature depen-
dences and the solubility products of [Ti]· [N] and [Ti]· [C] sharply
decrease with decreasing temperature. Accordingly, in operation with
high Ti hot metal, the solid solution Ti(N, C) precipitates from the metal
in the lower temperature region of the hearth.
It is well known that, for large inputs of Ti0 2 into the furnace, so
called 'titanium bear' is formed and problems occur such as poor
fluidity of discharged metal, decrease in available volume of the hearth,
etc.
564 BLAST FURNACE PHENOMENA AND MODELLING
1.20
0.96
.'
072 . :- .,/.~::.:
;;;1 .:" :.~.
cJ2 ." :;, ":
0.48
....
:." .: ..
...
.'
0.24
ooLL--0-'--.06--0-'-.1-2--0-J..1-S-----'0.2-4----'0.30
%Ti
Because iron from the coke blast furnace contains considerably more
sulfur than that from the charcoal blast furnace, serious problems were
encountered with hot fracture. Assurance of sufficient desulfurization
in the furnace was therefore a most important matter for the blast
furnace operator.
The extent of desulfurization was detennined by observation of the
color reflected by a gray surface due to graphite precipitation as a result
of a high Si content. A white surface accompanied by low Si content was
an indication of high sulfur. In this way, the inverse correlation between
Si and S content has long been used to judge the quality of pig iron.
Thus it was quite natural that, when a scientific approach was
initiated to control modern blast furnace operation Si was used as a
measure of the thermal state of the furnace. In an early investigation of
the model of the thermal state of the blast furnace, IRSID carried out a
heat balance in the lower part of the furnace and developed a
correlation between excess heat and Si. 31
The Muchi model,32 which has a classical value as the first universal
model of the Si02reaction with a large temperature dependence, showed
a strong correlation between Si content and the thermal state of the
furnace.
Tsuchiya 33 proposed a dynamic model of the blast furnace which was
composed of five reaction zones, each with a representative composition
and temperature. The solid temperature in the high temperature zone
was identified as a variable, while the other factors were assumed
constant. Using blast furnace operating data, he found a good
correlation between the solid temperature in the high temperature zone
and %Si. Although the model was quite simple, the correlation between
Si and the thermal state of the furnace was clearly shown.
Meanwhile an appreciable advance was made in operating tech-
nology of large blast furnaces, namely the use of highly basic sintered
ores. Through efforts for reduction of fuel costs in the blast furnace, the
production of hot metal with high temperature and low Si content
became possible (contrary to past performance). As a result, an attempt
was made to understand the behavior of the lower part of the furnace
through the reaction ofSi, and the mechanism ofSi transfer via SiO was
proposed.
Hatano et al. 34 developed a blast furnace model based on adding the
SiO mechanism to Tsuchiya's model. They assumed that Si in the gas
phase was absorbed by liquid metal droplets in the lower region of the
blast furnace, and that the height of the region ML, reflected the thermal
566 BLAST FURNACE PHENOMENA AND MODELLING
state of the furnace and resulted in the correlation with %Si. Figure 7.3.1
demonstrates an example of this analysis. For different capacities, a
good correlation between the height of the melting zone and %Si is
shown.
Through these analyses, a deeper understanding of softening and
melting of the burden has been obtained.
. /,
1.20
"..--,
",,"" D \
/
/" 0 a I
.;' 0 DO I
'aDDD 01
, aD I
0.90 ,/D a ap
, Dr
, I
" C BF
o
11" 0.60
E
<J)
0.30
Fig. 7.3.1. Comparison of actual %Si with calculated value based on the Si
transfer model.
7.3.2.1. Introduction
Silicon, sulfur and manganese charged into the blast furnace are
eventually partitioned between slag and metal tapped out of the furnace.
The practical partition ratios of these three elements, however, are not
uniquely determined under given thermodynamic conditions, and vary
with operational conditions. This suggests that the transfer reactions of
Si, Sand Mn do not take place in the same region; in particular, the Si
transfer reaction occurs mainly in the region from the surface of the slag
layer to the level where iron ores melt, i.e. in the coke bed in the lower
THE LOWER REGION OF THE BLAST FURNACE 567
part of the furnace, where molten slag and metal droplets are
descending. If the region that governs the partition of Si, Sand Mn
between slag and metal is known, the physical and chemical conditions
in this region can be estimated from practical partition ratios of the
three elements. Accordingly, the degrees to which the partition reactions
have proceeded are important in judging variations in the condition of
the lower region.
A method for estimating the volume of the coke bed in the lower
region, i.e. the volume of the dropping zone and the amount of
unreduced ferrous oxide descending into the hearth, is presented below.
01
SiO ' C Cohesive
~~Si I co zone
Dropping
zone ~~6C>::
bl
"'-
Hearth S i 2e---J"S~
Mn' I j 2e--~Mn
(ii) The region ofMn transfer into iron and S transfer into slag: slag
layer in the hearth through which iron droplets are trickling
By the use of the above four equations, the equilibrium partition ratios
of Si, Sand Mn can be expressed: 35
31221
10gL~i 210gPeo - -T-+ 20·70 (7.3.5)
1·79(%CaO) + 1·24(%MgO)
10gL~ = 1.35 1.66(%Si02) + 0.33(%Al20 3)
8130
-logPco - -T- + 4·15 (7.3.6)
15226
10gL~n = -logPco - - T - + 10·88 (7.3.7)
FeO" FeO"
Temp. • Temp. • (5"1<- 2' 2e, IMn!) j 2e-~
Hearth
Heat
loss Slog ~ Slog """-
comp L,./ camp Lv'
* tCp,( Cp.g: ratio of thermal COpoclty of condensed phase flow to thaI of gas flow)
Fig. 7.3.3. Factors influencing hot metal temperature, R Si , R Mn and Rs. Filled
arrows, strong factors; unfilled arrows, weaker factors.
~~ ::~ ~1 350 ~w
4501~ - !
,. o ~ '" vr: 1 X
/rX r~
., 38 : 70
o~ 36 '-
...-- I
J
5O '~
34 ,--'-~--'----'
' - I.....
,! I,
10 II 12 I 2 3 10 11 12 I 2 3
'75 76 75 76
Fig. 7.3.4. Relationships between operational factors and R Si , RMn and Rs.
Almost the same correlation between ore/coke and indices (B) and
(C) is also observed in daily operation, as shown in Fig. 7.3.5 (Chiba No.
6 furnace). The figure shows the correlation before and after a
temporary shut-down.
Using a mathematical simulation of the blast furnace, the above
correlation can be explained through the change in the average height
of the dropping zone, which is governed by the thermal flow ratio. 36, 37
(b) Comparison of different furnaces. Characteristic features of the
differences of RSi and Rs between the three furnaces in Fig. 7.3.4 are as
follows. In contrast with NO.5 furnace (with low Rs in spite of high RsJ,
for No. 3 furnace RSi was the smallest of an, while Rs was the highest. These
phenomena occurred because the burden descent was irregular for No.5
furnace, but smooth for No. 3 furnace. In a furnace with unstable
burden descent, FeO is not sufficiently reduced in the lower region, even
if the average height of the dropping zone is controlled at a high valve.
As a matter of fact, No.5 furnace was operated during the above period,
with alternate formation and peeling-off of scaffolds, and the ore/coke
THE LOWER REGION OF THE BLAST FURNACE 573
300
o
... ,,;""p------O .... - .................O 0
~ 200 O---~----_O___
o 0--
-D-
--/5--0-"
...... 0""'/0 0 ... - _______~--O- .. ..JJ
300 • o
100
r2 200
100
~ 40 [
o 3.0
Fig. 7.3.5. Relationships between ore/coke and RSi and Rs before and after
shutting down.
o Co'e
~3 _ L 3 • O re
' '--> ,
3 A
;~--~:" l',":"~
2
; ~~'
'1 ~ ~wO--Q,
~ I ~
0 ' , ~ • •
Z I 2 3 • 5 6 7 8 9 10 I 2 3 • 5 6 7 8 9 10 o I 2 3 4 5 6 7 9 10
Till,ng POSlllOn of thule
10
__
CO,
"-0-_
---'>--0
10 / CO,
3 5 9 10 9 10 9 10
Cenler Wall
Fig. 7.3.6. Conceptual shapes of cohesive zone and the corresponding radial
gas distribution patterns.
1%1
53 = 2: (I%COli - 1%CO,l i J
ou
10
I, = 3, 5, 7, 9, 101
0"""
0'
u co ""
'0 _____ --o()l-------l----~-_-_t:::g
..o-_------.cr----
C02 /cr"--'"
,,~,"
d/
__ - " -___ -'------'-_--'---~_ _L__'----~_"__...J
5 9 10
ICenterl IW all 1
50
Fig. 7.3.8. Relationship between RslRsi and gas distribution index, S3-1O'
vice versa (Fig. 7.3.6, C). Figure 7.3.8 shows the relationship between the
gas index, S3-1O, and R siR Si, and each point in the figure is the 5-1O-day
averaged value. As expected, negative slope was obtained; this suggests
that the shape of the cohesive zone, including the level of the root, can
be monitored by Rs/Rsi and Rs especially in the case of low fuel rate
operation.
+
o 2hw
r (Tw
1
_ UJ
TI) + 7CjTj~rf3k.iRi
+ ~al(- flHJR i
1
(7.3.15)
where 1 refers to one of the four phases gas (g), solid (s), metal (m), slag
(sl), and j refers to the three of these phases; i represents one of the
reactions: indirect reduction of ore, solution loss, direct reduction of ore,
melting of metal and ferrous oxide, melting of gangue material,
carburization of molten iron, SiO gas generation, Si absorption by
molten iron; and k represents the reacting components.
The variables are represented by: X, concentration of component; P *,
mass of the phase considered in the unit volume of the packed column;
e, time; V, actual flow rate (upward flow is taken as positive); Z, height
(up is positive); R, reaction rate; C, specific heat; T, temperature; r,
furnace radius; (- flH), heat of reaction.
Also, f3~\ is a coefficient which represents the mass transfer resulting
from the reaction, which either enters from another phase into the
considered phase (> 0) or exits the considered phase for j phase « 0), h j
are heat transfer coefficients between the j phase and the 1phase;A j . 1 are
the effective interfacial areas; hw is the heat transfer coefficient between
the gas and the furnace wall; Tw is the wall temperature; 0 1 is the
proportion of heat transferred to the furnace wall; a l is the reaction heat
of the phase considered.
THE LOWER REGION OF THE BLAST FURNACE 577
dX
dZ
k = (~~f3k(j}·R
j i ' I
- Xk~k ~~f3~)·R-\IG
j i
I ... iJ I
(7.3.17)
= _
dTg
dZ !f(CjTj CgTg)~ f f3(j)URi
+ hg,sAg,s(Ts - TJ
+ (2hwlr) (Tw - Tg)]lCgG (7.3.18)
where
ag = 0,
Here, the heat transfer between gas and liquid phases is so little in
comparison with that between gas and solid phases, as well as solid and
liquid phases, that it can be neglected.
(c) Differential mass balance equation for solid phase. When substances
in the solid phases disappear due to gas-solid and solid-liquid
reactions, the following equation is obtained, if the bulk densities of ore
and coke (Po and Pc) remain constant:
oVs _
+ ~~f3c,iR/p
(j) (j)
.:JZ - ~~f3o,iR/po (7.3.19)
v J I J I
where f3~:i andf3~:i are mass coefficients of substances exiting from ore or
coke layer to phase j. By substitution of eqn (7.3.19) into eqn (7.3.14), the
following equations are obtained:
ops + V op; =
V
.:J8 s .:JZ
C/
(1 - p;)~~f3(j);R + (1 - P;\)~~f3(j)'R
p0
"J 1
0, I P
01
"J 1
o. I I
(7.3.20)
578 BLAST FURNACE PHENOMENA AND MODELLING
(7.3.21)
(d) Differential heat balance equation for solid phase. For reactions
involving the solid phase, only the disappearance of a substance is
considered. This leads to eqn (7.3.22) on the basis of the fourth term on
the right-hand side of eqn (7.3.15) being equal to CsTsp:(iJV.liJZ);
iJC.liJZ = O,c5 s = 0; as = 1 for gas-solid reaction, while as = 0 for solid-
liquid reaction.
iJTs iJTs
iJ() + Vs iJZ = [hg.sAg.s(Tg - Ts) + hs.mAs.m(Tm - Ts)
+ hs.sIAs.sI(TsI - Ts) + ~as(- AHi)Rd/Csp:
1
(7.3.22)
(e) Differential mass balance equations for metal and slag phases. If the
formed melts are retained in the voids of the packed column until
melting is completed (i.e. the melting fraction is unity), the melts
descend at the same velocity as the solid, Vs. Metal and slag volume
fractions with respect to the unit volume of the packed column,H! and
H~, can then be obtained through the following equations obtained
from eqn (7.3.14):
(7.3.23)
Substituting eqn (7.3.19) into the above equations and integrating them
in the melting zone leads to the following equations at the lower
boundary of the melting zone, which show the volume flow rate of metal
and slag, U m and Usb including the sign of V:
Um = -Hm·Vm = -H:;'·Vs (7.3.25)
U sl = - HsI" VsI = - H sI · Vs (7.3.26)
Here H m, Hsb Vm and V sI respectively represent the hold-up and the
actual linear velocity, in the dropping zone, of metal and slag. If the
variation of U m and Usb due to the Si transfer reaction after dropping
starts, is minimal, Um and Usb and hence H m and Hsb are taken to be
THE LOWER REGION OF THE BLAST FURNACE 579
constant on the same stream line (from eqns (7.3.49) and (7.3.50), hence
for V m and V sl :
(7.3.27)
(7.3.28)
(f) Differential heat balance equation for metal and slag phases. If
am = asl = 1, with respect to the gas-liquid and solid-liquid reactions,
eqn (7.3.15) and eqn (7.3.27) lead to the following equations:
aTm V aTm _ (- t:.. H 6)R6 + hs.nAs,m(Ts - Tm)
.:Jll + m.:JZ - C mPm H m C mPm H m (7.3.29)
V(l V
TABLE 7.3.1
Integrands in Each Phase
t
Z + 3, 6Z
s .
-1
Q> ~l ~:---
-1 \'" ...,.o~
~ >- \ ''0 0",
Z+2·6Z
\f,<~
\ ~;--" ~>
\~.............
,
",
,0/
\
''\. Z +6Z
"- \
,, '\.'",
, \
Z
'~
8 8+68 8+2'68
Fig. 7.3.9. Lines from method of characteristics,
Repeated calculations of the above cycle yield the values of gas phase
variables at each of the points overtime f), and the values ofthe variables
of solid, slag and metal phases over time f) + ~f). Those at the Z position
on the f) + ~f) axis are determined by interpolation. All the variables on
the plane (Z, f)) can be obtained in the same manner until the
longitudinal distribution of the variables converges to a certain
condition.
(g) Temperature van'ation ofmolten iron and slag dun'ng tapping, over time
interval ~f). The temperature of metal and slag during tapping can be
calculated from the following equations on the basis of a given heat loss
per unit area of the hearth and the assumption of complete mixing of
metal and slag in the hearth. Here, the average thicknesses of the layers
of residual metal and slag are calculated from the tapping schedule.
Meanwhile, temperature and variations of components are continuously
calculated (Fig. 7.3.10).
THE LOWER REGION OF THE BLAST FURNACE 581
Tout
sl uslT~ + lTr 2U s1 !1()T:'l- Q~!1()/CsIPSI
(7.3.33)
Usl + lTr2Us1 !1()
vout UmX~i + lTr2Urn!1()~Si
ASi (7.3.34)
Urn + lTr 2U rn !1()
Open ~ Plugged
T", Psi ~
/
cf
Q
where
QL = lTrQ + 2lTr(h m + hb)Q
Q~ 2lTrhslQ
urn = lTr2(hrn e + hb)
Usl lTr2h s1 e
Urn()b«()b + ()m - ()sl)
hrn = 2«()b + ()rn)
Us1«()b + ()m - ()Sl) hO
hsl 2e + sl
582 BLAST FURNACE PHENOMENA AND MODELLING
(h) Equation for gas pressure drop. The Ergun equation41 is employed,
where the particle diameter represents the averaged value in accordance
with the ore/coke ratio; the void fraction is 0-4 in the lumpy zone, O' 3 in
the melting zone and 0·45 in the dropping zone. In the calculation, the
gas pressure below tuyere level is assumed to be constant.
C + CO, ~ 2CO
/I CO t FeO ~ CO, + Fe
C+CO, ~ 2CO
FeO[II+C ~ CO,-Felll
C ~ C
Fe [51 ~ Fe [II
Gangue [51 ~ Slog III
SiO -i- CO ~ SiO, + C
V. MnO + C ~ Mn f CO
TiO,+2C ~ TI '2CO
1/2 P2 0s -i- 5/2 C ~ 1: + 5/2 CO
(a) Lumpy zone. The rate equation for iron oxide reduction is based on
the unreacted core model, similar to that developed by Muchi et al. 42 The
model assumes stepwise reduction from Fe203 to Fe304, FeO and Fe. It
also includes the contributions of gas-film and intraparticle gas
diffusion. The carbon solution-loss reaction of coke with CO2 gas is
given by a rate equation 43 which takes into account the effects of particle
diameter and gas-film diffusion.
THE LOWER REGION OF THE BLAST FURNACE 583
(b) Cohesive zone. This zone consists of coke and ore layers, molten
metal and slag. The temperature of the solid phase ranges from l250°C
to the melt-down temperature of iron ores, T drop ' In addition to the above
two reactions, it is assumed that the melting rate of ore depends on the
rate of heat transfer from the gas to the ore bed. At the moment of
melting, both the reduction of molten iron oxide to metal and the
carburization of metal occur simultaneously, and molten slag and
metal are heated up to the temperature, T drop ' Meanwhile, at the lower
end of the cohesive zone, excess SiO gas is oxidized by CO to Si0 2, and
the heat of reaction heats up the gas phase around the zone.
(c) Dropping zone. The rate of SiO gas evolution due to the reaction of
molten slag with coke, Si02 (l) + C(s) - SiO(g) + CO(g), is determined
by eqns (7.3.35)-(7.3.37).44 For eqns (7.3.36) and (7.3.39) temperature is
taken as K. while for the other equations °C is used exclusively.
Rs = ksAs.SlaSi~ (7.3.35)
ks = 3·57 X 1018 exp (-l77000/RT) (7.3.36)
Here, aSi02 is given by the equation below, derived by Taylor,4S as a
function of slag composition and temperature.
-10gasio2 = (8'0 X 1O- 6T + 0'0228)B - 9·31 X 1O- 4 T + 0·797 (7.3.37)
where
it is assumed that evolution of SiO gas from Si02in coke ash continues,
and thus Si0 2content in coke ash decreases, until the melting point of
the residual ash reaches the temperature T" as shown schematically in
Fig. 7.3.12. Since the reaction heat of Si0 2 reduction is assumed to be
contributed by the gas phase, the temperature of gas leaving the
combustion zone, T g , is correspondingly lower than TFT. The following
equation gives P SiO in the combustion gas:
(7.3.41)
1900 .
e 1800
o
0.
OJ
c
~ 1700
X ~
5,00
____._._ _ [ I
5,0, I AI 2 0 3 ' CoO
(e) Hearth. The present model does not deal with the reaction rate of
MnO, Ti0 2 and P20S reduction. Consequently, the reduction of the
above oxides into metal is assumed to occur in the hearth to provide the
amount specified in the metal so as to satisfy the mass and heat
balances. The corresponding coke consumption is taken into account
and the heat of reaction is provided by the sensible heat of gas
circulating in the hearth. It is assumed that Si transfer by the slag-metal
reaction can be disregarded.
THE LOWER REGION OF THE BLAST FURNACE 585
Metal Gangue
/SiO+CO ~ SiO,+C
v,
C + S,O, ~ CO + SiO
Firstly, for the reaction between SiO gas and dropping metal, an
empirical equation developed by Umada et al.,48 which gives the
effective interfacial area between the gas and liquid phases, is
applied:
(7.3.43)
586 BLAST FURNACE PHENOMENA AND MODELLING
a/lsl g
x (PSIU~I)02(CTc)0'75J (7.3.44)
aCTsl CTsl
(7.3.49)
THE LOWER REGION OF THE BLAST FURNACE 587
~,d
(7,3.50)
TABLE 7,3.2
Physical Properties of Metal and Slag
J Ceo, C N2 , PSI{),
\ p", T", G
obtained. Thus, when gas reaches tuyere level from the hearth, the
composition and temperature of the liquid phases at time () + !l..(} will be
given. At tuyere level the mixing of the gas rising from the hearth and the
gas from the combustion zone, which is a fraction (1 - a) of the total
combustion gas, provides the composition and temperature at tuyere
level. As cited above, in the dropping zone above tuyere level, the
variation of gas phase variables in the axial direction at time () and also
the axial distribution of liquid and solid phases at time () + !l..(} are
provided. The characteristic line above the melting zone is only that of
the solid phase, in which the distribution of variables is obtained in a
similar manner. When the calculation reaches the furnace top, since the
stock level at time () + !l..(} has lowered by Vs . !l..(}, a new charge into the
resultant space is necessary.
In this calculation, the furnace radius r is kept constant, the fraction a
is taken as 0·05 and the heat transfer coefficient from the furnace wall,
hw, is taken as 12 kcallm 2 • h . DC so that a blast furnace with a 1845 m 3
capacity has a heat loss of approximately 1· 3 X 105 kcal per ton of pig
THE LOWER REGION OF THE BLAST FURNACE 589
iron. Separately, the heat loss flux in the hearth zone is assumed to be
8000 kcallm 2 • h.
To calculate the steady state in-furnace condition, the charging and
blast conditions are kept constant. With an appropriate initial in-
furnace distribution, the gas composition at the furnace top rapidly
approaches a final value after a 4 h calculation; during which the whole
packed bed is replaced by a new charge from the top to the melting zone.
After approximately 24 h, the melting zone becomes stabilized and
thereafter, in the succeeding simulation of 48 h, the tapping temperature
does not vary by more than 2-3°C. In this analysis, the solution which is
obtained after a simulation time of 24 h is used to provide the Si
concentration under steady state operation.
7.3.3.4. Results
As a base for actual operation simulation, an operation without oil,
Chiba No.3 furnace (1845 m3 ) producing steelmaking iron, has been
considered. The calculations were carried out by changing the various
factors in the base operation condition.
The value of the heat transfer coefficient between gas and solid
phases influences the temperature distribution in the furnace, and that
between liquid and solid phases controls the temperature of metal and
slag. These two parameters were chosen so that the calculated
temperature distribution and hot metal temperature coincide with the
actual values.
Both the actual and calculated values are shown in Table 7.3.3. Si
contents and temperatures of hot metal are in fairly good agreement.
TABLE 7.3.3
Comparison of Actual and Calculated Values
] 20
e
.g
~
OJ 15
o
-;;,
E
g
Q)
u
c
~
o
5
O.T. level-i>
o TH level -i>
, ,
04
E 6
~
~ \'"
\~
~ 4 '~,
~ ~ .~'r,
g 2 : I Si
1::c T", TSI : ~
I I
~ I
o 0 T.H
,--!> i ~,
1400 1500 1600
liq. temp. lOCI
the related factors with hot metal temperature is shown in Fig. 7.3.17,
based on the change of O/C in series A A hot metal temperature of
l490°C corresponds to O/C = 3·6, and by a stepwise decrease in O/C to
3·4, both temperature and Si content increase in the same order. Here,
TABLE 7.3.4
Calculation Cases
Series O/C(-) ThrC) Dpo (mm) T drop rC)
A 3·4 1250 12 1400
3·5 1250 12 1400
3·6 1250 12 1400
B 3·4 1200 12 1400
3·4 1150 12 1400
3·4 1100 12 1400
3·4 1050 12 1400
C 3·4 1250 15 1400
3·4 1250 18 1400
D 3·4 1150 15 1400
3·4 1050 15 1400
E 3-3 1150 15 1400
3·3 1050 15 1400
F 3·4 1250 15 1450
3-3 1250 15 1450
xl0:l
: :r [
~ ::[ 4
05l 07
-
</)
0-
~ 0.5
0.3
0.1 L----1_--L_...L_.L-_L----1_-l
1470 1490 1510 1530
Hot metal temp. lOCI
0.70
060
0.50
- OAO
~
';; 1
0.30
0.20
0.10
o : Melt·down temp. 1450'C
O L-L-L-~~~-L~~~~~_ _~
7.3.3.5. Discussion
As a result of the application of the empirical equations employed in the
preceding section, the metal and slag flows in the dropping zone can be
considered as follows. In the case of a daily production of 4000 tons at
Chiba No.3 furnace (productivity of 2·17 t/m3 • day), total hold-ups of
metal and slag are estimated to be around 0·018 and 0·025 m 3/m 3(bed),
respectively, and the wetted areas of coke 2· 3 and 2·1 m2/m3(bed),
respectively. Consequently, the average contact thickness of the two
594 BLAST FURNACE PHENOMENA AND MODELLING
flows with respect to the wetted areas turns out to be 7· 8 and 12 mm. The
fraction of dynamic hold-up to total hold-up is small, particularly in the
case of metal. Therefore it is estimated that metal flow oozes down
between the small pools of static hold-up in which the metal is mixed
successively. Consequently, the average down-flow rate of metal is as
small as 20 m/h. This is also true in the case of slag. It is also estimated
that for both metal and slag the effective interfacial area between gas
and liquid phases is approximately four times the wetted area.
In the preceding section, the temperature dependence ofSi content in
metal is different for the case of change oftuyere zone temperature and
that of thermal flow ratio change in conjunction with O/C and 17co.
Expressed another way, in the former case the hot metal temperature
has a high relative variation, while in the latter case the Si concentration
has the greatest variation. Here, a comparison is conducted, using real
furnace data and data calculated from the model, to see what variations
will occur in the Si content and hot metal temperature by changes in
operating conditions. In the real furnace, the relationship between Si
content and thermal flow ratio, with the hot metal temperature level
constant, indicates that increases in the thermal flow ratio decrease the
Si content, as in the dotted area in Fig. 7.3.19 (Mizushima No.2
furnace.).57 The relationship between thermal flow ratio and TFT
(Mizushima No.2 furnace) at constant hot metal temperature is shown
in Fig. 7.3.20; this kind of relationship could have been derived
theoretically. 58 In the case of a real furnace, TFT is calculated under the
assumption that the coke temperature in front of the tuyere is o· 75 times
that of TFT. The results calculated in the preceding sections can be
~
Vii
0.4
0.3
~OX?Yi.
0.2
o 8
Mizushima No.2 BF
() : Low Tr:T period
0.1
o low Si period
0.89 r - - - - - - - - - - - - - - - - - - - ,
0.88 Mlzushimo No.2 BF
() low TFT period low HMT
0.86 0 low 5, period
~.: .. :-.: .. :
()
: : -.:"
"2 0.84
3
o
c=
{) 0.82
~ High HMT
E
"
;:': 0.80
0.78
Fig. 7.3.20. Factors influencing the hot metal temperature at Mizushima No.2
furnace.
"I
1-160
1420 '0'
I
2100 2200 2300 2400 :;500
Therll:ol f,o v. ' C(]~IO I I T FT
Fig. 7.3.21. Transformation of the results into the values under the constant hot
metal temperature.
596 BLAST FURNACE PHENOMENA AND MODELLING
between thermal flow ratio and TFT at constant hot metal temperature.
Both Figs 7.3.22 and 7.3.23 show strikingly similar trends to those
measured on actual furnaces. Expressed another way, this model has
successfully demonstrated the mechanism by which Si concentration
and molten iron temperature are determined in the furnace in the long
term, e.g. 10 days, 30 days, etc.
In the case of Mizushima furnace No.2, a low Si experiment was
conducted in the following manner, as shown in Figs 7.3.19 and 7.3.20.
0.6
\,
0.5
'"
() '--
~-(J) 7520'C
\~--.::.
'0 ---~~()~
~
°--°_
~ 0.4 \Aseries
Vii
7480'C
0.3
Fig. 7.3.22. Calculated relationship between thermal flow ratio and Si.
0.95
() 0.90
o
E
"
.:: 085
0.80 L -_ _--'-,--_~::::_----:::-;'.
2300 2400 2500 2600
TFT lOCI
Fig. 7.3.23. Calculated relationship between thermal flow ratio and TFT under
constant HMT.
THE LOWER REGION OF THE BLAST FURNACE 597
(1) Firstly, the TFT was lowered and Ole reduced. (2) Secondly, Ole
was raised with TFT maintained as low as possible. As a result, a Si
content of 0·2% was obtained as the lO-day average. In the case of (1)
above, decreasing TFT below 2200 0 e greatly reduced the Si concen-
tration in the metal, in agreement with the relationship shown in
Fig. 7.3.19. This phenomenon suggests a deviation from the relationship
in Fig. 7.3.22, in which Si content is controlled by the absorption rate of
SiO gas into metal, to another relationship in which the SiO generation
rate is dominant. In this model, lowering the blast temperature to the
low Ole conditions, as e.g. in the case of foundry pig iron production,
will reduce the SiO gas concentration in front ofthe tuyere; details will
be discussed elsewhere. In the case of (2) above, as shown in Fig. 7.3.20,
the molten iron temperature could be maintained at a comparatively
high thermal flow ratio with TFT lowered. This is attributable to the
possibility of maintaining a constant hot metal temperature at higher
thermal flow ratio in the case of an ole increase, as is seen in the plot for
series A in Fig. 7.3.23, possibly due to a decrease in the required amount
of heat per ton of pig iron.
7.4. NOTATION
REFERENCES
605
606 BLAST FURNACE PHENOMENA AND MODELLING
Ikg/ II Il/m3·dayi
700 2.0
~
f!
-i
v
600
1.8
-u 1.6 Z.
5 500 :~
1.4 -g
~ o
-u
400 1.2 c':
Burden ratio
{Sinter + Pe!l~~ _,..-x-" 1.0
/~
1....... ---.-. ..... + I'CI 0.8
/ k .............. 1,300
~~~
1 !
Burden ratio ),200
ff -........
k
...
x
~ ~-'
(Sinter)
1,100
1.000 Cl
900 a5
(;
1,000
BOO
~
~
0.. 500
1955 )960 1965 1970 1975 1979
Source: JISF
purchased and generated in the plant in the future on the basis of (i)
coke rate of 475 kg/t hot metal, (ii) iron/steel ratio of 1, and (iii) LD gas
recovery rate of 100 Nm 3/tcrude steel. Net amounts of purchased energy
based on coal and in-plant energy use in the future are 5560 X 103 kcallt
crude steel and 5210 X 103 kcallt crude steel, respectively. The difference,
350 X 1~ kcal, can therefore be sold to outside firms. In order to attain
the 'future', the 'present' net energy consumption, 5620 X 103 kcallt
crude steel, must be decreased by 410 X 103 kcallt crude steel. As shown
in the 'future' part of the figure, if 10% offuel, 5% of electricity and 10% of
steam can be saved (a total of 230 X l~ kcallt crude steel), and if
recovery of waste heat is put into effect (180 X 103 kcallt crude steel),
both oil consumption and electricity purchase would become zero - a
steelplant without oil.
This energy situation has placed the blast furnace in the role of a
carbon monoxide generator which supplies carbonaceous energy to the
mill and, moreover, a raw material, CO, for organic syntheses, for
instance, C 1 chemistry. Low fuel rate operation is therefore no longer a
necessity for decreasing the cost of final steel products, although it still is
Energy outflow
ISoi d to ou tside f irmsl
350 Unit, X 10' kcal / t·Crude Steel
5,560
~
>-l
In · plan t 2,400
5.210 ~
Combustion fue l - - I • I. Power - --"';"'- !
Fulure [ COnSumed]
~
tT1
1,400 1,000 energy
~
1 - - - - - -1,400 • ' ....
,
, 20
Iranmoking o
process
energy loss
1,420 840
Present
[ COnSumed ]
I
;l
etc . 710 energy
) n
::r:
----·2 .710---~ 1--- - - - - 1 . 5 5 0 I I, 1,200 W', [~J 2,910 z
ot""
Premises , BF coke rat io = 475 kg ton of p ig iron D By ·product gas
o
Iron steel (o ti o = 1 ~
l DG recovery rate = 100 NM' ton of crude stee l 12,000 Kco l per NM'I tt-1{~1 Waste heol recovery
Consumed energy Ipresentl is based on Kowasoki Steel Corporation ~
Purchased energy
M izush imo Works 1978 data . ~
- - - specification
------ adjustment through feedback information
measuring objectives of
varlobles measurement
pressure of blast
temperature of hearth
Fig. 8.4a. Blast furnace sensors that are already widely applied for detecting
in-furnace conditions.
f~':'':~'~'
i
: Ihl(kneSS
of fire brick 11---_
1
_ _ _ _ _ _ _ _ _ _ _ _----1 0105S and/or erosion of fire
bricks on the wall and In the
I
hearth
[~"a~g~le'~el~d~ele~"~a'=:J_--------------1 Oresiduol
hearth
amount of slag in the I
I slag flow meter I Otapped amount of slog I
I tuyere thermocouple o flome temperature in front of
the tuyere
I
Ibl to be developed and under development
• 1966-1970
Year of { 0 1971-1975
blowdown
x 1976 -1980
.
1,000 2,000 3,000 4,000 5,000
12
.. .,.. . o·
",10
<>
.
.. . .
00
.." ....' :~ .:
~8
,
.. 6 -.~ . ." ...... . .
0
.:
.. .
0
v
.J.... • 'l' ,
.
g ,
.2 4
~ 2
Fig. 8.5. Relationship between furnace life and effective inner volume,!
vzzzv~ [J
I I I ! I I I ! I I I
P7ZZZ~
I I I I I I
0
I I !
987654321 987654321
Chute-pos
Center _ - - - - _ . Wall
~
I' 0 00 x x x
•• 00°0 x\.
• Periphery
., °0
. ...
"
o Mirldle • 0
X Center
• o
o
x
•
] 10
•• •• Ox
Ox
E o xx
l' o
o
ill
C
o
o
20
Tuyere
15
10
10 12 14
lorge slips ~
o Stable
"
o
70 10 15 55 59
50 Small slips
100
pulverized refractory materials on the inner wall from the inside of the
furnace may be helpful. However, this technology should be accompanied
by the development of technical know-how for temporarily emptying
the furnace to tuyere level.
I
,,
I
I
Eroded line
\,!...-----+---~='
As shown in Fig. 8.8, within a few decades the fraction of aged people
(older than 65) will comprise nearly 20% of the Japanese population.
Because of this and the leveling-off of iron and steel production, the
average age of workers in Japanese steel plants will be at least 40. In
addition, in industrialized countries, steel plants are less attractive to
young people.
Although instrumentation and equipment for the blast furnace have
been considerably modernized, hard jobs under hot conditions, such as
drilling tap-holes, tapping, and repairing/replacing tuyeres and runners,
remain.
In consequence, such jobs will have to be mechanized completely,
preferably with industrial remote-controlled robots. In such industrial
fields as vehicle building, electronics and others, industrial robots have
already been successfully introduced.
70
80
60
40
I~ 1m 1m 1m I~ 1m 1m 1= 1m 1m
Source: JISF
Fig. 8.9. Decrease of silicon content in pig iron, averaged for all Japanese blast
furnaces. l
~....,
Na 2c03i
recovery
1 ~
t slag-off
L ~
tTl
hot metal hot metal simultaneous
oxidation hot metol :;;;
blast 0.2-05°'oS, S, < 005% desulohurizotion
of r-- 0.015%P converter
furnace r-- OI%P I--- r--- O.i qop f-f+ ond r-- o
silicon 0005%5
0.03-0.04%S 0.03-0.04%S dephosphorizotion
t
, I
'"
I I
, I
~oz
I iro~ oxide I I 02 I @
and ior witl-]out
oxygen flux
n
~
ot""
Fig. 8.10. A slag-less steelmaking process using sodium carbonate. o
~
0\
....-
--..J
618 BLAST FURNACE PHENOMENA AND MODELLING
EE)lhCluSI gas
0,.
orher
moreno Is
.----coke~
[5-7.2k[ - 01[1
co~
[39- 59k[ - 01[1
bouxl.,e 2
f----- { clay
alumina
fuel
I
I
I
electricity I coke,
CO
ore
I
I
I
I
I
t
refining ...
, - - - - crude alloy crude 4---0{~3
metal
AI [I [0.6-0.7kl- 01[1
Fe 0251
5, 01 I
cf
conventional process
~5.1 kl--oil/I-AI
REFERENCES
1. E. Iwamura, Report of Proceedings 1980. Fourteenth Annual Conference,
International Iron and Steel Institute (1981), p. 122.
2. T. Fukushima, H. Yamada, T. Kobayashi, Y. Niwa, T. Furukawa and B. lino,
Tetsu-to-Hagane, 67(1981), S70.
3. T. Yamamoto, H. Kanoshima, T. Takahashi, K Ogata and Y. Hayashi,
Tetsu-to-Hagane, 67(1981), S74.
4. K Sano and T. Miyazaki, Tetsu-to-Hagane, 66(1980), S36.
5. S. Taguchi, H. Katayama, N. Tsuchiya, K Okabe, K Tanaka and
K Okumura, Stahl u. Eisen, 101(1981),1173.
6. T. Uchida and S. Komatsu (Eds), Kasshiki no Jidai, Tsusho Sangyo
Chosakai (1980), p. 49.
7. K Okumura, T. Kawai, H. Marushima, H. Takahashi and 1. Kurihara,
Tetsu-to-Hagane, 66(1980), 1956.
8. R. Nakagawa, T. Ueda, S. Yoshimatsu, T. Mitsui, 1. Uehara, A. Fukuzawa
and Y. Nakamura, Kinzoku Zairyo Gijutsu Kenkyusho Kenkyu Hokoku,
10(1967), 557.
9. M. Dokiya, Kinzoku, 51(8) (1981), 21.
INDEX
621
622 INDEX