STUDY ON CARBON PICKUP VARIATION IN HOT METAL

Bona fide record of work done by

S. SUBBURAYALU (16Y434)
During academic period of 2018-2019

Dissertation submitted in partial fulfillment of the requirements for the degree of

BACHELOR OF ENGINEERING

Branch: METALLURGICAL ENGINEERING

DEPARTMENT OF METALLURGICAL ENGINEERING

PSG COLLEGE OF TECHNOLOGY

(Autonomous Institution)
COIMBATORE – 641 004

I
 CERTIFICATE
OFFICE OF THE DEPUTY GENERAL MANAGER
BLAST FURNACE DEPARTMENT

This is to certify that the project report entitled “CARBON PICKUP

VARIATION IN HOT METAL # BF-1&2” being submitted in partial
fulfillment of the requirements of the degree of Bachelor of Engineering in
Metallurgical Engineering is the original work carried by him under the
guidance and supervision of the under signed, during the academic session
2018-2019. This project is a result of his own effort and has not been
submitted to any other university or institute for the award of any other
degree or diploma to the best of our knowledge.

Place: - JSW Salem Mr. V Sudharsan

Date: - DGM, Blast Furnace

Mr. S K Kalidhasan
DM, BF (Operation)
 Acknowledgement

ACKNOWLEDGEMENT

The satisfaction that accompanies on successful completion of a task would be

incomplete without mention of the people who are responsible for it. In preparing these
proceedings I was fortunate to receive valuable guidance, support, suggestions and
assistance from my guide and his colleagues. I greatly appreciate their generosity in devoting
their valuable time to help me in pursuing this project.

It is with feelings of profound thankfulness and deep sense of gratitude that I

acknowledge the invaluable guidance and consistent encouragement rendered to me by
Mr. V Sudharsan [DGM-Blast furnace], Mr. Sadhasivam [Senior Manager–BF
(Operations)], Mr. Srinivasan [Manager – BF (Operations)] and Mr. S. K. Kalidhasan [DM-
Blast furnace] JSW Salem works, Salem. They spared their valuable time from their busy
schedule for me and helped me by providing guidance for the project.

I also express my thanks to the staff, technicians and people working in Control Room
of BF-2 and BF-1 of JSW Steel Ltd,Salem works for their critical comments, suggestions,
support & co-operation which ultimately helped me and without their guidance this project
would not be completed in the desired manner, within the scheduled time frame.

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 Abstract

STUDY ON CARBON PICKUP VARIATION IN HOTMETAL

ABSTRACT

In blast furnace (BF), one of the aspect that determines the quality of the hot metal is percentage
of carbon present in the hot metal and well-being of blast furnace. There are many factors
contributing to carbon[C] pickup in hot metal like raw material and product chemistry, blast
furnace operating parameters and slag behaviour. The low percentage of carbon in hot metal is
effect of blast furnace operation deviation from its efficient operation. In order to study and
find out the deviation, data of blast furnace parameters, raw material and product chemistry
and slag behaviours are collected and analysed. Data organization is one of tedious works to
getting accurate results. Organized data are analysed in both technically and statistically, such
as carbon mass balance, direct (DR) and indirect reduction (IDR), Rist diagram, trend charts
and multiple regression analysis (MRA). By analysing and establishing relationship between
the Carbon in hot metal and others parameters, carbon variation in hot metal was studied.

Keywords: Carbon pickup, C-Mass Balance, IDR &DR, Rist Diagram, Trend Charts, MRA,
MRA Parameters.
 Table of contents

TABLE OF CONTENTS
CHAPTERS PAGE NO.
TITLE PAGE…………………………………………………………………………… i
CERTIFICATE……………………………………………………………………........ ii
ACKNOWLEDGEMENT……………………………………………………………… iii
ABSTRACT…………………………………………………………………………….. iv
TABLE OF CONTENT………………………………………………………………… v
LIST OF TABLES……………………………………………………………………… Vii
LIST OF FIGURES…………………………………………………………………….. viii
1. INTRODUCTION………………………………………………… 1
1.1. BLAST FURNACE………………………………………………. 1
1.1.1. BASIC PROFILE OF THE BLAST FURNACE……………….. 2
2. LITERATURE SURVEY………………………………………… 7
2.1. INTRODUCTION………………………………………………… 7
2.2. MINERALS INFLUENCING CARBON PICKUP……………… 7
2.3. COKE REACTIVITY…………………………………………….. 9
2.4. BEHAVIOR OF BLAST FURNACE..……………………….. 10
2.5. SIDE REACTIONS………………………………………………. 16
2.6. DEADMAN CLEANLINESS INDEX…………………………… 16
3. OBJECTIVE……………………………………………………… 18
4. METHODOLOGY……………………………………………….. 19
5. DATA COLLECTION…………………………………………… 20
5.1. RAW MATERIAL ANALYSIS………………………………….. 20
5.2. PRODUCT AND BY-PRODUCT ANALYSIS………………… 21
5.3. COKE AND COAL ANALYSIS…………………….…………… 22
5.4. BLAST FURNACE OPERATION AND PARAMETERS……. 24
6. DATA ANALYSIS………………………………………………... 26
6.1. CARBON-MASS BALANCE……………………………………. 26
6.2. DIRECT AND INDIRECT REDUCITON ANALYSIS………… 28
6.2.1. IDR & DR CALCULATIONS……………………………………. 28
6.3. TREND CHARTS………………………………………………... 30
6.4. RIST DIAGRAM…………………………………………………. 36
6.5. MULTIPLE REGRESSION ANALYSIS……………………….. 39
6.5.1. BLAST FURNACE 2…………………………………………… 39
6.5.2. BLAST FURNACE 1…………………………………………….. 41

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 Table of contents

6.6. COMPARISON OF DATA………………………………………. 43

7. SUGGESTIONS ………………………………………………… 45
8. BIBLIOGRAPHY ………………………………………………… 47

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 Table of contents

LIST OF TABLES
TABLE NO TABLE TITLE PAGE NO
1.1 SALIENT FEATURES OF BLAST FURNACE -2……………… 5
1.2 SALIENT FEATURES OF BLAST FURNACE -1……………… 6
2.1 FACTORS INFLUENCING CARBON DISSOLUTION………... 13
5.1 SINTER ANALYSIS REPORT…………………………………… 20
5.2 COKE ANALYSIS REPORT……………………………………... 21
5.3 ORE ANALYSIS REPORT……………………………………….. 21
5.4 HOT METAL ANALYSIS REPORT……………………………… 21
5.5 TOP GAS ANALYSIS…………………………………………….. 22
5.6 SLAG ANALYSIS…………………………………………………. 22
5.7 MICUM DRUM INDEX RESULTS………………………………. 23
5.8 CSR and CRI analysis……………………………………………. 23
5.9 BLAST FURNACE OPERATING PARAMETERS…………….. 24
6.1 CARBON MASS BALANCE SHEET……………………………. 27
6.2 IDR &DR CALCULATION FOR BF-2…………………………… 29
6.3 IDR &DR CALCULATION FOR BF-1…………………………… 30
6.4 REGRESSION ANALYSIS REPORT MRA 1………………….. 39
6.5 REGRESSION ANALYSIS REPORT MRA 2………………….. 40
6.6 REGRESSION ANALYSIS REPORT MRA 1………………….. 41
6.7 REGRESSION ANALYSIS REPORT MRA 2………………….. 42
6.8 COMPARISON OF BF 1 & BF 2 PARAMETERS……………... 43

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 Table of contents

LIST OF FIGURES
FIG FIGURE TITLE PAGE
NO NO
1.1 SCHEMATIC VIEW OF BLAST FURNACE 3
ZONES…………………………...……
1.2 SCHEMATIC VIEW OF BURDEN LAYER, REACTIONS AND
DISTRIBUTION OF IRON BEARING 3
MATERIALS…………………………………………………………
1.3 OVERVIEW OF 4
PROCESS……………………………………………………..
1.4 CENTRAL COKE CHARGING IN BLAST 5
FURNACE…………………………………
1.5 BLAST FURNACE SETUP IN JSW SALEM LTD…………………………. 7
2.1 BURDEN LAYER AND COKE DISTRIBUTION…………………………… 7
2.2 IRON ORE……………………………………………………………………... 8
2.3 QUARTZITE……………………………………………………………………. 8
2.4 DRUM TEST…………………………………………………………………… 10
2.5 COKE ( RAW MATERIAL HANDLING YARD )……………………………. 10
2.6 THE DESCENDING OF COKE MODIFIES THE MEAN SIZE, DI,
MICRO STRENGTH REACTIVITY AND ASH
CONTENT……………………………………………………………………. 12
2.7 DIFFERENT TYPES OF LANCE TO ENHANCE THE EFFICIENCY OF
BLAST FURNACE…………………………………………………………… 14
2.8 PULVERIZED COAL INJECTION………………………………………….. 15
4.1 METHODOLOGY………………………………………………………………. 19
5.1 MICUM DRUM INDEX……………………………………………………….. 22
5.2 COKE ………………………………………………………………………….. 23
6.1 TREND CHART OF C% IN HOT METAL………………………………….. 31
6.2 TREND CHART OF BASICITY OF SLAG…………………………………. 31
6.3 TREND CHART OF HOT METAL TEMPERATURE……………………… 31
6.4 TREND CHART OF BLAST VOLUME……………………………………… 31
6.5 TREND CHART OF OXYGEN ENRICHMENT…………………………… 32
6.6 TREND CHART OF RAFT…………………………………………………… 32
6.7 TREND CHART OF SINTER FEO…………………………………………… 32
6.8 TREND CHART OF DCI……………………………………………………… 32

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 Table of contents

6.9 TREND CHART OF CARBON SATURATION……………………………… 33

6.10 TREND CHART OF VISCOSITY……………………………………………. 33
6.11 TREND CHART OF IDR………………………………………………………. 33
6.12 TREND CHART OF DR………………………………………………………. 33
6.13 TREND CHART OF CWI……………………………………………………… 34
6.14 TREND CHART OF MN PARTITION……………………………………….. 34
6.15 TREND CHART OF PERMEABILITY……………………………………….. 34
6.16 TREND CHART OF CRI………………………………………………………. 34
6.17 TREND CHART OF CSR…………………………………………………….. 35
6.18 TREND CHART OF NUT COKE RATE…………………………………… 35
6.19 TREND CHART OF COAL RATE…………………………………………… 35
6.20 TREND CHART OF ALKALI IN SLAG………………………………………. 35
6.21 FE-O-C EQUILIBRIUM DIAGRAM…………………………………………… 36
6.22 RIST DIAGRAM FOR BF-2…………………………………………………… 37
6.23 RIST DIAGRAM FOR BF-1………………………………………………….. 38
6.24 MRA 1 (NORMAL PROBABILITY PLOT)…………………………………… 39
6.25 MRA ( HISTOGRAM )………………………………………………………… 40
6.26 MRA 1 (NORMAL PROBABILITY PLOT)…………………………………… 40
6.27 MRA ( HISTOGRAM )………………………………………………………… 41
6.28 MRA 1 (NORMAL PROBABILITY PLOT)…………………………………… 41
6.29 MRA ( HISTOGRAM )………………………………………………………… 42
6.30 MRA 1 (NORMAL PROBABILITY PLOT)…………………………………… 42
6.31 MRA ( HISTOGRAM )…………………………………………………………. 43

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Chapter 1 Introduction

CHAPTER 1
INTRODUCTION
The production of steels and pig iron requires more heat utilization, that can be attained
only in blast furnaces. The degree of heat utilization is more in blast furnace, because of
counter current reactions. Simply, Blast furnace is about counter current heat exchanging
apparatus. The source of iron (Fe) comes from its oxide ores. Most commonly used iron ores
are hematite (Fe2O3) and magnetite (Fe3O4). Ore is a combination of iron oxide, alumina,
silica and some other oxides. Other than ores, iron oxides are also added in the form of sinters.
Sintering, which contains iron and iron oxide (FeO), is pre-reduction process for converting
hematite (Fe2O3) to wustite (FeO) and iron (Fe). It will influence the fuel rate and blast furnace
efficiency.

Reducing atmosphere is maintained in blast furnace. In order to reduce the hematite

into magnetite, magnetite into wustite and wustite to pure iron(Fe). Each time iron ore
reduction takes some thermal energy as well as chemical energy to attain its pure form. The
reaction rate is enhanced by injecting steam, oxygen enriched hot blast and pulverized coal.
Some reactions contribute in temperature raise (Exothermic reactions) and some reactions
will utilise thermal energy (endothermic reactions) to proceed.

The heat is supplied by burning of coke, coal and nutcoke. Blast furnace consist of
different zones and processing stages. Coke is a heterogeneous material and it contains
different forms of carbonaceous material, mineral components, detrital, syngenetic and
epigenetic and a pore structure which is strongly dependent on amount of volatile matter
present [4] [2]. The primary functions of coke are to provide a structural support to the burden,
to convert iron oxide into metallic iron and serving as a fuel for blast furnace [4]. Quality of
coke decides the burden descend and permeability of the burden; if it collapses the liquid and
gas permeability is reduced and the carbon dioxide production per tonne of hot metal is
increased. Figure 1.1 represents the burden layers and coke distribution. So, the coke dictates
the efficiency of the furnace [4].

1.1 BLAST FURNACE PROFILE

The burden materials (iron bearing materials, coke and nut coke) are charged from the
top of furnace with the aid of skip cars. The cylindrical top portion is called throat and below
the throat, stack or shaft is present with increasing diameter. Belly is the next region of furnace
after stack. Belly has increased diameter arrangement. After belly, bosh and hearth regions

1
Chapter 1 Introduction

are located. Accumulated molten metal and slag are present here. The refractories used in
different zones of furnace are,
1. High alumina brick -Stack
2. Gunite -Stack
3. Phosphate clay brick -Stack
4. SiC ramming mix -Hearth
5. Burned microporous alumina graphite brick -Bosh
6. Clay castable -Stack
7. Anhydrous press in mortar -Belly
8. Semi graphite carbon brick -Hearth
9. Micro-pore carbon brick -Hearth
10. Composite brown corundum bricks -Hearth
11. Carbon ramming material -Hearth
12. Low cement corundum ramming material -Hearth
13. Composite brown corundum of ceramic cup -Hearth
The schematic diagram of blast furnace is shown in figure 1.1,1.2 and the blast furnace
used in JSW Salem Ltd is shown in figure 1.5. The overall process of material flow and central
coke charging are shown in figure 1.3 and 1.4.
1.1.1 Basic profile of the Blast Furnace
• Throat - This is the region, where the charged raw materials are falling inside the
Furnace. Irregular falling can be controlled by bell less top system. The chute helps
to distribute the raw material in furnace equally. Any improper falling of the raw
material, damage the side wall of throat.

• Stack – This part starts below throat and extends till the belly. This is designed to
accommodate the thermal and volumetric expansions of the charge materials.
Thermal reserve zone comes in stack region. The counter current temperature is
uniform at this region. Descending rate of the charge in this region is higher, due to
the volumetric expansion throughout the stack.

• Belly – This is the part where diameter is maximum and it is designed because
melting and fusing starts here. Cohesive zone, dripping zone and dead-man zone
are formed only in belly region. Relative to the stack, the temperature in this zone is
very high. To accommodate volume expansion from solid to liquid, belly is designed
with large diameter.

• Bosh – This part starts below the belly and extends up to the hearth. In this portion
liquid metal and slag drips down to hearth.

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Chapter 1 Introduction

• Hearth – . This cylindrical part collects the molten metal and slag. Periodical tapping
is essential to drain the molten metal and slag.

• The salient features of blast furnaces are tabulated in table 1.1 and 1.2.

Fig 1.1 Schematic view of blast furnace zones

Fig 1.2 Schematic view of burden layer, reactions and distribution of iron bearing materials

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Chapter 1 Introduction

Ground Coke oven Sinter

hopper(Iron plant( Coke) plant(Sinter)
ore, Flux)

RMHS, Bunkers

Ore
Stock house, Screening
Fines

Flue dust,
GCP BLAST FURNACE

Cast House

Slag Hot metal BF-gas

Steel Melting Shop

(SMS)

Slag granulation
plant
Other plant
Gas cleaning usages (CCM,
Dust catcher
plant BRM, BR,
Stoves, etc)

Fig 1.3 Overview of process

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Chapter 1 Introduction

Fig 1.4 Central coke charging in blast furnace

Table 1.1 Salient features of blast furnace-2

S.no Description UOM Value

1. Furnace Useful volume m3 640

2. Furnace working volume m3 550

3. Productivity T/m3/day 3.4

4. No.of tuyere - 16

5. PCI rate Kg/THM 150

6. Tuyere diameter mm 115

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Chapter 1 Introduction

7. Hearth diameter m 6.15

8. Charging system Bell less top

9. GCP Dry GCP

10. Stove Top combustion

Table 1.2 Salient features of blast furnace-1

S.no Description UOM Value

1. Furnace useful volume m3 550

2. Furnace working volume m3 450

3. Production per day T/m3/day 1000-1067.361

4. No.of tuyere - 14

5. PCI rate Kg/THM 150

6. Tuyere diameter mm 110

7. Hearth diameter m 5.10

8. GCP Wet GCP

9. Stove Top combustion

10. Charging System Bell Less Top

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Chapter 1 Introduction

Fig 1.5 Blast furnace 2, JSW Salem Ltd

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Chapter 2 Literature survey

CHAPTER 2
LITERATURE SURVEY
2.1 INTRODUCTION

Based on its graphitizable, carbon is classified into two types, they are
Anisotropic carbon (<0.2micro m) is graphitizable and its reflectance varies with the
orientation of the plane of polarisation of the incoming light and Isotropic carbon
(>0.2micro m) which is non-graphitizable, amorphous and whose reflectance do not
vary with the orientation of the plane of polarisation of the incoming light [2].

Fig.2.1 Burden layer and coke distribution

2.2 MINERAL INFLUENCING CARBON PICKUP

Iron oxide was found to enhance the carburization rates and lowers the ash
fusion temperature [2]. Other additives and oxides were found to reduce the
dissolution rate. Sulphur containing solids are wetted better than the aluminium
containing solids. More sulphur in the hot metal retard the wetting of carbon and fe
melt. Carburisation rate was slower for cokes containing high amount of alkalis (5% to
10 % of K2CO3) [2]. The addition of alkali to coke increase the reactivity of coke.
Minerals and cation concentration in the coke assess the reactivity of coke [4]. The

7
Chapter 2 Literature survey

effect of minerals is ranked according to their presence and effects, towards the coke
reactivity. The various reaction zones are shown in figure 2.1.

K2CO3 > Na2CO3 > CaCO3 > MgCO3 = MgO > FeCO3 > FeS2 > Al2O3 = SiO2

Reactivity of the coke is reduced by kaolinite, quartz, potash feldspar and soda
feldspar and increased by pyrite, gypsum, metallic iron, tyrolite, magnetite, lime and
hematite [4]. Figure 2.2 and 2.3 represents the flux and iron ore which contains the
above mentioned minerals.

Fig 2.2 Iron Ore

Fig 2.3 Quartzite

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Chapter 2 Literature survey

The Fe cation concentration reactivity is decreased with increasing of si cation

concentration. Based on Si to Fe cation concentration ratio vs FWC (Fractional Weight
change), it shows the linear relationship. The variables are magnetite iron cation
concentration at constant particle size or constant cation concentration vs
carbonaceous matter in the coke [4].

Low fusion of temperature of ash favourable for creating/ expose a new surface
area of coke (carbon) to liquid iron. This will increase the rate of dissolution of C. More
addition of CaO, will reduce the fusion temperature of ash [2].

2.3 COKE REACTIVITY

Coke reactivity is known to affect carbon consumption in a blast furnace through

a shift in the transition of FeO–Fe reduction equilibrium point [6]. Under conditions that
maintain appropriate coke strength, higher the coke reactivity, lower is the thermal
reserve zone temperature due to the endothermic reaction of intensified coke
gasification. Thus, CO gas utilization moves to a higher end shifting the equilibrium
point of FeO–Fe reduction from W to W0 and reducing associated energy
consumption. The characteristics of coke dissolution into hot metal were also found to
influence the descending rates for coke and the final level of carburization of liquid
metal [6].
Pseudo CRI (Coke Reactivity Index) was conducted to determine the porosity,
carbon structure and mineral distribution through the coke [4]. The most common tests
are used in industries is Japanese Drum index, M40 (cracking resistance index), M10
(abrasive resistance index), CRI (coke reactivity index) and CSR (coke strength after
reaction). European metallurgical process: M40: >78–>88, M10: <5.0–<8.0, CSR: >60,
CRI: 20–30. blast furnaces in China as: M40: >78–>86, M10: <6.0–<8.0, CSR: >58–
>65, and CRI: <25–<28 [6]. In M40 the greater the value, the greater the strength but
in M10 the lesser the value, the greater the strength. Figure 2.4 shows the actual drum
index testing. Greater the CRI value, more the reactivity to carbon dioxide and CSR
value [7]. Coke with different CRI was experimented to show the effect of CRI to rate
of carbon dissolution. CRI increase with decrease in the temperature at which the
reaction start. Figure 3.1 shows the actual drum test.

9
Chapter 2 Literature survey

Fig. 2.4 Drum test

Only coke exists in a solid state below the softening and melting zone, and
makes up more than 70% of the total volume of the slag layer. The liquid and gaseous
permeability in the blast furnace is therefore determined to a great extent by the
strength of coke [6]. Figure 2.5 depicts the coke used in blast furnace.

Fig 2.5 Coke ( raw material handling yard)

2.4 BEHAVIOUR OF BLAST FURNACE

The raceway adiabatic flame temperature (RAFT) and blast velocity both had
a significant influence on coke degradation. The cracking of coke due to thermal stress
occurred more easily under a higher RAFT, and the formation of an inactive dead-man
and the degradation of coke could be prevented at an optimal velocity. While some of
the coke is consumed through direct reduction, a significant proportion of coke
dissolves into hot metal as carburizer. During this movement, coke undergoes
mechanical actions such as crashing, extruding and frazzle, and chemical reactions

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Chapter 2 Literature survey

such as carbon solution loss, reduction reactions with SiO2 and FeO in early slag,
mineral erosion and carbon dissolution into hot metal, followed by a hammering in the
raceway area. All these actions combine together to cause degradation/consumption
of coke in the blast furnace [6]. The strength of coke gets significantly reduced during
its descent in the blast furnace leading to a number of problems and it’s schematically
shown in figure 2.6.
1. In the lumpy zone, a reduction in coke strength will increase the generation of
coke fines and dust that increases the resistance to airflow;
2. In the cohesive zone, the generation of coke fines occurring in the coke layer
will lead to an increase in the airflow resistance, which in-turn affects the
distribution of gas in the furnace causing slipping and hanging;
3. In the drippy zone, coke fines and molten iron bind together and detain
additional melt in this zone, which increases the airflow resistance and demerits
the distribution of gas flow.
4. In the tuyere level, it causes a reduction in the raceway depth along with an
increase in the height of the raceway, and the permeability worsens with
additional melt and slag depositing under the raceway that will burn and block
the tuyeres
5. In the hearth, air cannot blow through the heart of the hearth, which lowers the
hearth temperature along with deterioration of liquidity of hot metal and slag.

Basic elements such as Fe, Ca, Mg and alkalis are active at high temperatures
and may affect coke texture. An increase in ash basicity has a catalytic influence on
coke reactivity. On the other hand, silicates (Si, Al and alkalis) in coke are inactive at
high temperatures. This alkali cycle acts as a catalyst for coke gasification reactions
in the blast furnace, speeding up the coke gasification and greatly reducing the size
and density of coke with a detrimental influence on blast furnace operations [6].
Although coke consumption in the blast furnace is affected by the alkali input,
a reduction in coke strength cannot be explained with changing coke strength after
reaction (CSR) and coke reactivity index (CRI) values and was not affected by the
alkalis present in coke initially. The saturation solubility C[solid] in the melt depends
on temperature and on the concentration of various alloying elements present in
molten iron [6].

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Chapter 2 Literature survey

Fig 2.6 The descending of coke modifies the mean size, DI, micro strength, reactivity and ash
content

Carbon dissolution from graphite is reduced by sulphur in the hot metal. Sulphur
lowers the carbon diffusivity co-efficient and limits the carbon diffusion [2]. Generally,
carbon dissolution occurs in two manners, they are

1. Dissociation of carbon from its crystal structure (interfacial reaction).

2. Mass transfer of carbon atoms from boundary layer into the bulk liquid iron (rate
limiting step).
The overall reaction rate is represented by [1]
I. Mass transfer (nelson equation)
II. Effective co-efficient of diffusion
III. Reaction rate

1st order kinetic equation is used to determine the dissolution rate. The
increased crystalline size shows the increased rate of dissolution of carbon. The
ordered arrangement of carbon atoms enhances the carbon dissolution. Scherer’s
equation is used to calculate the crystallite size. After conclusion on crystalline size,
there is no influence of crystalline size [2].
In a coke packed bed, the melting of reduced iron occurs at the contacting
points between the coke and reduced iron. At high temperature, liquid iron is initially

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Chapter 2 Literature survey

generated by carburization at these points because melting temperature of iron is

lowered by carbon pickup.so, the rate of melting depends on carbon dissolution [5].
Only by the direct reduction coke was consumed. The iron droplets interact with the
coke and direct reduction will proceed further [9].

The factors influencing carbon dissolution is temperature, alloying elements,

wettability, particle size of solid and ash in coke. Interdependency between theses
parameters are listed in table 2.1 [5].

Table 2.1 Factors influencing carbon dissolution

S.no Factors Affecting Factors

1. Temperature Solid structure,
Adsorption blockages,
Liquid solid wettability,
Side reactions.
2. Solid structure Liquid and solid wettability,
Temperature.
3. Adsorption blockages Temperature,
side reactions,
Alloying elements,
Liquid and solid wettability.
4. Alloying elements Adsorption blockages,
side reactions,
Liquid and solid wettability.
5. Liquid agitation side reactions.
6. Liquid and solid wettability Temperature,
Solid structure,
Alloying elements,
side reactions,
Particle size of the solid,
Ash.
7. Particle size of the solid Liquid and solid wettability.
8. Ash side reactions,

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Chapter 2 Literature survey

Liquid and solid wettability.

9. Side reactions Temperature,
Adsorption blockages,
Alloying elements,
Liquid agitation,
Ash.

Presence of other elements like, si, s, Mn affects the activity co-efficient of

carbon in the liquid, carbon saturation level and viscosity of the liquid [5].
Carbon particle size will affect the contact area particularly during PCI [5]. The
pulverised coal injection through lance, increase the efficiency of the furnace is shown
in figure 2.7 and figure 2.8 represents the actual PCI system JSW Salem Ltd. By
improving lance condition (single, double and eccentric lance lance). The effective
blast furnace operation is achieved by Reduction in amount of slag. This condition
controlled by reducing the coke ash content, increased temperature, ore and pellets.

Fig.2.7 Different types of lance used to enhance the efficiency of blast furnace

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Chapter 2 Literature survey

Fig 2.8 pulverized coal injection

The side reactions will not directly affect the carbon dissolution rate, but they
will indirectly affect carbon dissolution rate by the reaction with dissolved carbon or by
changing compositions of the liquid and the ash [5]. The major component in ash is
silica, and the silica reduction will occur when fused ash contacts the liquid through
the reaction:
(SiO2) + 2[C] [Si] + {2CO} ……………………. Reaction.1
This reaction will take a portion of carbon away from liquid, increase silicon in
the liquid, and reduce silica in the ash. The former will cause confusion when observing
the carbon dissolution rate, the second will cause the carbon saturation content to
change with time during the dissolution process, for example, will not be able to be
integrated, and the last will decrease the viscosity of the ash. Sulphur usually presents
in carbonaceous materials, either in carbon structure or in ash phase. The sulphur
pickup from coke or coal occurs during carbon dissolution [5]. The rate of sulphur
pickup due to carbon dissolution is considered to be in proportion to the carbon
dissolution rate and sulphur/carbon ratio in coke. The sulphur pickup will change
carbon saturation content and sulphur adsorption blockage during carbon dissolution

15
Chapter 2 Literature survey

process. When fluxing materials such as CaO present in the system, following reaction
will occur to consume dissolved carbon and the product of this reaction, CaS, may
remain at the interface to reduce contact area [5].
[S] + [C] + (CaO) (CaS) + {CO}……….……Reaction.2
[S] + [C] + (MnO) (MnS) + {CO}…………... Reaction.3
CO generated from side reactions. Formation of CaS is more favourable than
MnS formation. after formation of CaS, the excess S reacts with Mn and forms the
MnS. MnS lowers the liquidus temperature. So, the amount of MnS decides the
temperature difference between the liquidus actual and liquidus temperature
change.in both the reactions dissolved carbon is involved. [6].

Carbon is affected by direct reactions only, because carbon involves the

reduction of oxides at tuyere level and carbon monoxide is generated through direct
reactions.
2.5 SIDE REACTIONS (DIRECT REACTIONS)
Carbon directly consumed by following reactions in the blast furnace,
[C] + {CO2} {2CO} ………………………………….... Reaction.4
(FeO) + [C] [Fe] + {CO}…………………………….... Reaction.5
(SiO2) + [2C] {SiO} + {CO}……………………….…..…Reaction.6
{SiO} + [C] [Si] + {CO}……………….…………....…Reaction.7
[C] + {O2} {CO2} ………...…………….……………. Reaction.8
[C] + {H2O} {CO} + {H2} …………………….………. Reaction.9
(MnO) + [C] [Mn] + {CO}……………………….….…Reaction.10
(P2O5) + [5C] [2P] + {5CO} …….………...……. ….…Reaction.11
(TiO2) + [2C] [Ti] + {2CO} ………………….………...Reaction.12
2.6 DEADMAN CLEANLINESS INDEX
The amount of carbon required for saturation is determined by the metal
temperature and the concentration of other elements also dissolved in the liquid iron.
Interactions between solute species occur at the atomic level and marked changes in
solute activities can arise. Carbon saturation in iron making small amount of Si, S, P
and Mn is used to determine the carbon content at saturation.

% C sat= 1.3 + 0.00257 HMT- 0.31%Si– 0.33%P – 0.4%S + 0.028%Mn (2.1)

16
Chapter 2 Literature survey

All concentrations are in weight percent and temperature is in degrees Celsius.

The departure of hot metal carbon content from the saturation value, ΔC is readily
determined.

ΔC = %Csat - % Cactual (2.2)

Because dirtying of the Deadman by slag is also possible, the hybrid dead-man
cleanliness index has been developed by combining the temperature sensitive term
and the C difference value with an expression describing sensitivity of the liquidus
temperature.

DCI = HMT + (1/0.00257) ΔC – (1430 – 190* (1.23 – (C/S))) (2.3)

17
Chapter 3 Objective

CHAPTER 3

OBJECTIVE
To find out the optimum operating parameters for controlling carbon pickup
variation and carbon dissolution rate in hot metal.

18
Chapter 4 Methodology

CHAPTER 4
METHODOLOGY
NOTE: Since JSW Salem going for TQM challenge, the project methodology is done as per TQM procedure.

Process observation

Problem identification

Literature survey

Data collection

Blast furnace Raw materials,

parameters products and by-
products chemistry

Data
analysis

Mass Trend Multiple Rist

balance charts regression diagram
analysis

Influencing No Non-influencing
Parameters parameters

Yes

Suggestions Conclusion
19
Chapter 5 Data collection

CHAPTER 5
DATA COLLECTION
Main and essential step in initiating the project is proper done collection. Any
abnormality or error in data collection will lead to wrong results. So, while collecting the data
proper care is given and data for normal days only taken to analyse the data for carbon pickup
variation. The following data are collected for carbon pickup variation analysis,

1. Raw material analysis ( Ore, Sinter, Flux and Coke),

2. Product and By-Product analysis,
3. Coke and Coal analysis,
4. Blast furnace operation and parameters.

5.1 RAW MATERIAL ANALYSIS

Iron ore, Coke, coal, nut coke, sinter and fluxes are the main raw materials for blast
furnace. where in sinter plant and coke is converted from coal in coke ovens. The process
parameters and elemental presence were analysed by optical emission spectroscopy and
obtained from supplier. Other than elemental analysis, some more analysis also done in wet
laboratory. The elemental analysis and testing results are listed in table 5.1, 5.2 and 5.3.

Table 5.1 Sinter analysis report

Description Composition (%)
Fe(T) 52-55
FeO 9-11
SiO2 5-7
CaO 10-13
MgO 2
Al2O3 2-3
Indexes Resultant value
RDI(-3.15mm) 23-26
RI 64-67
TI 71-76
AI 4-6

20
Chapter 5 Data collection

Table 5.2 Coke analysis report

Description Presence (%)
Moisture 2-5
Volatile matter 1 – 1.2
Ash 12-13
Fixed carbon 86-87
CRI 23-25
CSR 65-67
M40 88-90
M10 5-6

Table 5.3 Lump Ore analysis report

Description Composition (%)
LOI 1-6
Fe 59-66
SiO2 2-6
Al2O3 2 -4
P 0.0410-0.1445
Na2O 0.0130-0.0185
K2O 0.0058-0.1097
MnO 0.0680-2.0330
TiO2 0.11
Moisture 3-5
TI 77-85

5.2. PRODUCT AND BY PRODUCT ANALYSIS

Hot metal analysis is done by optical emission spectrometer. During tapping, hot metal
sample is taken by pouring the hot metal in copper mould and sent to lab for analysis. The
casted testing sample is polished in wet laboratory and elemental analysis is carried out by
OES. Range of hot metal analysis is given in the table.
Table 5.4 Hot metal analysis
Elements Composition (%)
C 4.2-4.4
Si 0.3-0.8
Ti 0.4-0.01

21
Chapter 5 Data collection

P 0.13-0.18
S 0.06 max
Mn 0.2-1

The Blast furnace gas analysis is carried out by orsat apparatus. This equipment holds
four chambers. Each one contains of KOH, KOH+C6H6O3, CuCl+KCl and CuO. To identify
the components in gas, sample of blast furnace gas is taken. Top gas is allowed to pass
through each chamber and giving wash or rinsing effect amount of species (CO, CO2, O2 and
H) is identified. Remaining quantity is occupied by N2. Table 5.5 is the top gas analysis report
Table 5.5 top gas analysis Table 5.6 Slag analysis
gases Composition (%) Description Composition
CO 21-22
(%)
CO2 20-21
CaO 33 -34
O2 1
MgO 8.5-9.5
H2 5
SiO2 32-33
N2 Remaining
Al2O3 18-20
Na2O3+K2O 0.1
MnO 0.5
S 0.8

5.3 COKE AND COAL ANALYSIS

Maceral properties of coal varies with coal ranks and presence of organic constituents.
The morphological variation affects the coal properties and solution of carbon in hot metal.
Maceral properties are distinguishable under microscopic testing, based on their reflectance
and morphology. There are three type of maceral groups, they are vitrinite, exinite and
inertinite. Each type of maceral group holds unique property. Vitrinite is more reactivity, exinite
have more hydrogen content compared to other group and inertinite is non-reactive.
Micum drum index test:
The testing process of Micum drum index, and coke is shown in figure 5.1 and 5.2.

Fig 5.1 Micum Drum index

22
Chapter 5 Data collection

Fig 5.2 Coke

Table 5.7 Micum drum index results

Date M40 M10

01-apr-2018 88.7 5.8

04-apr-2018 88.4 5.7
05-apr-2018 88.6 5.8
06-apr-2018 88.7 5.8
07-apr-2018 88.6 5.9
08-apr-2018 88.5 5.7
10-apr-2018 88.6 5.8
11-apr-2018 88.4 5.7
12-apr-2018 88.7 5.8
13-apr-2018 88.5 5.9
14-apr-2018 88.6 6.0
15-apr-2018 88.5 6.1
17-apr-2018 88.4 6.0
18-apr-2018 88.7 6.1
19-apr-2018 88.6 6.0
20-apr-2018 88.7 6.2
21-apr-2018 88.5 6.1
22-apr-2018 88.6 6.0
23-apr-2018 88.7 6.0

High temperature characteristics:

Table 5.8 CSR and CRI analysis

Date CRI CSR

01-apr-2018 24 65.78
04-apr-2018 23.5 66.33
05-apr-2018 23.75 65.57
06-apr-2018 24 65.78

23
Chapter 5 Data collection

07-apr-2018 23.5 65.68

08-apr-2018 24 65.46
10-apr-2018 23 66.23
11-apr-2018 23.5 66.01
12-apr-2018 24 65.46
13-apr-2018 24 65.78
14-apr-2018 23.5 66.01
15-apr-2018 23.5 66.33
17-apr-2018 23 66.23
18-apr-2018 24 65.46
19-apr-2018 24.5 65.23
20-apr-2018 23.75 65.57

5.4. BLAST FURNACE OPERATION AND PARAMETERS

Healthy blast furnace is detected by several factors,
1. Consistency in blast volume
2. Good tapping practice
3. Good quality of raw material (Iron ore, Sinter, Coke)
4. Fines input to furnace
5. Healthiness of all medical and electrical operation parameters.
6. Stringent monitoring of blast furnace operating parameters.
The deviation in the above-mentioned factors lead to abnormality in the furnace
operation and thereby affecting the productivity and quality of hot metal. The parameters
involved in blast furnace operation is listed in table 5.6.
Table 5.9 Blast furnace operating parameters
S.no Parameters
1. Blast volume
2. RAFT
3. O2
4. Steam
5. Tuyere velocity
6. CWI
7. PWI
8. Fuel rate
9. Coal rate
10. Metal drain rate
11. Central coke charge
12. BF gas generation
13. Flux input

24
Chapter 5 Data collection

14. Slag volume

15. Slag Basicity
16. Dust rate
17. Ore input
18. Flux input
19. Furnace Permeability
20. MPS of Ore
21. MPS of Sinter
22. MPS of Coke
23. Mn partition
24. Steam injection rate
25. Sinter %
26. Top pressure

25
Chapter 6 Data analysis

CHAPTER 6
DATA ANALYSIS
6.1 CARBON-MASS BALANCE

The coke, nut coke and coal contain fixed amount of carbon content in it. That carbon
will induce the heat in blast furnace, dissolve in hot metal and gets converted in to gaseous
form. Fuel rate is addition of all carbon containing substances (coke, coal and nut coke). CO
and CO2 are the gaseous form of carbon obtained in blast furnace. Whatever, C input giving
in to the furnace, is recovered as hot metal, gas, DC dust and GCP dust. So, carbon mass
balance is ensured for healthy furnace operation.

Carbon mass balance is typical technic to identify the carbon in burden, hot metal,
gases, dust catcher and gas cleaning plant. According to first law of thermodynamics, energy
can be transformed from one form to another form; all the systems obey this condition. Thus,
carbon is transformed from solid to gaseous form by giving out energy.

There is an equilibrium constraint maintained in all reactions, according to that, every

reaction is well balanced.

Following steps are done to prove the carbon mass is balanced in furnace#2 and table 6.1
shows the C-mass balance.

Step 1: Calculate the carbon in coal, coke and nut coke (N.C).

1. Carbon in Coal = [Weight of Coal* (F.C/100)]/ Total production = Carbon Kg/THM in

Coal
2. Carbon in N.C = [Weight of N.C* (F.C/100)]/ Total production =Carbon Kg/THM in
N.C
3. Carbon in Coke = [Weight of Coke*(F.C/100)]/ Total production =Carbon Kg/THM in
Coke
Total carbon in raw material = C in (coal + coke + nutcoke)

Step 2: Calculate the carbon in CO and CO2

C+O CO………………………………...…………. Reaction 6.1

C+O2 CO2…………………………………………...Reaction 6.2

(Based on these reactions, carbon in gaseous form is identified)

26
 Chapter 6 Data analysis

Carbon in CO and CO2 = [((% of CO + % OF CO2) / 100) *0.54*BF gas generation]/ Total
production

= Carbon in CO and CO2 kg/THM

Step 3: Calculate the Carbon in DC and GCP

1. C in DC = % of C * DC rate = C in DC kg/THM
2. C in GCP = % of C * Flue dust rate = C in DC kg/THM
Total carbon = C in DC + GCP
Step 4: Calculate the C in hot metal

C in Hot metal = % of C * Total production

Step 5: Calculate the carbon in input and carbon in output and difference can be found

Carbon in Input = C in Coal + C in nut coke + C in Coke

Carbon in Output = C in HM + C in gas + C in DC + C in GCP

Step 6: calculate the carbon utilization percentage

% of C utilized = [(C in input – C in output) / C in input] *100

Table 6.1 carbon mass balance sheet

Fuel rate (Kg/THM) Output Carbon (Kg/THM)

Total Total Carbon
C in C in Nut C in Hot C in BF
C in Coal carbon C in DC Cin GCP carbon utilized
coke coke metal gas
(Kg/TH input (Kg/TH (Kg/TH output (%)
(Kg/TH (Kg/TH (Kg/TH (Kg/TH
M) (Kg/TH M) M) (Kg/TH
M) M) M) M)
M) M)
361.9 88.5 13.4 463.8 83.5 373.1 1.5 3.8 461.8 99.6
354.1 95.7 13.0 462.8 82.3 369.4 2.3 1.8 455.9 98.5
349.4 96.3 13.2 458.9 82.3 372.7 1.8 2.2 459.0 100.0
354.5 94.9 13.6 463.0 81.9 372.7 1.4 2.7 458.7 99.1
364.9 89.7 9.9 464.5 78.3 370.9 1.2 2.9 453.3 97.6
391.2 66.9 8.7 466.8 80.9 369.7 1.6 2.3 454.5 97.4
382.7 75.4 8.6 466.8 64.9 413.8 1.6 2.7 483.0 103.5
362.3 88.9 8.5 459.7 78.5 370.5 1.8 1.7 452.5 98.4
354.4 92.9 9.2 456.5 80.4 379.6 1.8 2.1 463.9 101.6
348.3 96.1 9.1 453.5 79.2 380.0 2.1 1.9 463.3 102.2
359.5 89.4 9.3 458.2 76.7 358.4 1.6 1.8 438.4 95.7
388.6 69.6 9.0 467.2 67.9 389.8 1.7 1.7 461.1 98.7
464.2 0.0 10.7 474.9 76.3 370.7 1.7 3.0 451.7 95.1
363.9 69.7 16.6 450.3 75.3 387.6 2.7 2.1 467.7 103.9
451.2 0.0 18.3 469.5 58.0 412.8 2.7 2.2 475.6 101.3
450.3 0.0 16.6 466.9 61.7 407.1 1.7 2.4 472.7 101.3

27
 Chapter 6 Data analysis

450.2 0.0 17.0 467.2 63.9 405.8 1.7 3.1 474.6 101.6
Thus, all the input carbon level is almost matched with output carbon level.

6.2 DIRECT AND INDIRECT REDUCTION ANALYSIS

Direct reduction occurs at bottom zone of the furnace and indirect reduction occurs in
the stack zone. To improve the heat utilization increase, the indirect reduction shall be high
and it leads to lower the fuel rate. In direct reduction, solid carbon reacts with oxides and in
indirect reduction, gaseous form of carbon i.e CO reacts with oxides to produce Fe. Degree of
direct and indirect reduction in blast furnace decides the efficiency of furnace.

(FeO) + [C] [Fe] + {CO}…………………………………. Reaction 6.3

(3Fe2O3) + {CO} (2Fe3O4) + {CO2} ………...……….…Reaction 6.4

Reaction 6.3 is the direct reduction and 6.4 is the indirect reduction. Gas utilisation
shall be more as it leads to more carbon pickup in hot metal and lowers the fuel rate.

Ƞco = CO2 / (CO+CO2) (6.1)

The degree of direct and indirect reduction zone is calculated via nitrogen in the blast
furnace gas. Because the nitrogen is inert gas, by backward calculation, amount of oxygen
and carbon reacted is calculated. From that, approximately IDR and DR are estimated.

From IDR and DR, the amount of carbon required for reaction can be easily estimated.

6.2.1 IDR and DR calculations

Volume of N2 = % of N2 in BF Gas * Top gas volume

= Volume of N2 Nm3/THM

Volume of N2 in Top gas = Volume of N2 in blast

Volume of O2 in blast = [Volume of N2 in top gas * (21+ O2 enrichment)] / (100-(21+O2

enrichment))

Weight of O2 = Volume of O2 * 1.43

According to 2C + O2 -> 2CO, because solid carbon only involves direct reaction in
tuyere level.

C consumed at tuyere level = 24 * (weight of O2/32)

Therefore, C in IDR = C in Fuel rate - C consumed at tuyere level (Kg/THM).

28
Chapter 6 Data analysis

DR = C consumed at tuyere level (Kg/THM).

Weight of O2 removed by direct reduction is equal to

= DR * (16/12)

The percentage of DR = weight of O2 removed by DR * (100/ Total Fe – O present)

Normally, ideal blast furnace runs with 75% IDR and 25% DR. if, there is any variation,
it will affect the production and cause furnace abnormality. Table 6.2 and 6.3 are IDR & DR of
BF-2 and BF-1.

Table 6.2 IDR and DR calculation for BF-2

Weight
C burnt C C
Oxygen in weight of O2
Vol of N2 at consumed consumed
the blast of O2 removed IDR % DR %
tuyere for DR for IDR
by DR

Nm3/THM Nm3/THM Kg Kg/thm Kg/thm Kg Kg

928.1 318.0 454.8 341.1 120.7 341.1 161.0 46.8 53.2

935.1 319.4 456.8 342.6 113.3 342.6 151.1 44.2 55.8
923.6 316.9 453.2 339.9 119.0 339.9 158.7 46.4 53.6
926.4 318.8 455.9 341.9 116.8 341.9 155.7 45.5 54.5
930.0 318.1 454.9 341.1 112.2 341.1 149.6 43.8 56.2
932.7 319.5 457.0 342.7 111.8 342.7 149.1 43.4 56.6
990.7 294.2 420.8 315.6 167.4 315.6 223.2 65.4 34.6
964.4 286.4 409.6 307.2 145.3 307.2 193.7 56.5 43.5
924.6 299.2 427.9 320.9 143.0 320.9 190.6 55.5 44.5
934.9 313.0 447.7 335.7 127.5 335.7 170.1 49.4 50.6
893.1 299.9 428.8 321.6 116.8 321.6 155.7 45.2 54.8
978.1 326.4 466.8 350.1 111.0 350.1 148.0 43.1 56.9
963.9 297.3 425.1 318.9 132.8 318.9 177.1 51.6 48.4
966.0 279.6 399.9 299.9 167.8 299.9 223.8 65.2 34.8
1033.8 299.3 428.0 321.0 154.7 321.0 206.2 60.1 39.9
1024.0 289.1 413.5 310.1 162.6 310.1 216.9 63.0 37.0
1002.0 266.4 380.9 285.7 188.9 285.7 251.9 73.1 26.9

29
Chapter 6 Data analysis

Table 6.3 IDR and DR calculation for BF-1

Weight
C burnt C C
Oxygen in Weight of O2
Vol of N2 at consumed consumed IDR % DR%
the blast of O2 removed
tuyere for DR for IDR
by DR
Nm3/THM Nm3/THM Kg Kg/thm Kg/thm Kg Kg
1011.65 333.90 514.20 385.65 196.12 385.65 261.49 76 24
1012.25 333.80 514.06 385.54 196.57 385.54 262.10 76 24
933.14 307.58 473.67 355.25 230.54 355.25 307.39 89 11
1000.43 330.24 508.58 381.43 202.17 381.43 269.56 79 21
1001.50 330.24 508.56 381.42 202.68 381.42 270.24 79 21
997.65 329.07 506.76 380.07 205.37 380.07 273.82 80 20
1023.00 337.27 519.40 389.55 194.90 389.55 259.86 76 24
1011.01 333.40 513.44 385.08 195.51 385.08 260.68 76 24
1035.87 345.13 531.50 398.62 181.31 398.62 241.74 70 30
1021.59 340.63 524.57 393.43 185.77 393.43 247.69 72 28
968.94 323.12 497.61 373.21 206.88 373.21 275.85 80 20
973.94 324.63 499.93 374.95 201.34 374.95 268.45 78 22
947.14 315.08 485.23 363.92 211.83 363.92 282.43 82 18
985.48 327.67 504.61 378.46 197.84 378.46 263.79 77 23
990.99 330.52 509.00 381.75 193.77 381.75 258.37 75 25
977.56 325.78 501.70 376.28 197.98 376.28 263.97 77 23
975.49 324.51 499.75 374.81 194.39 374.81 259.18 75 25
987.19 329.14 506.87 380.16 188.95 380.16 251.93 73 27

6.3 STATISTICAL ANALYSIS

To compare the hot metal carbon and influencing factors, trend charts are used. Series
of trend charts are developed and stacked one by one for easy reference. Finally, the stacked
charts are compared and analysed technically and statistically from figure 6.1 to 6.12 shows
the relationship between the C and other parameters.

30
Chapter 6 Data analysis

%C
4.60
4.50
4.40
4.30
4.20
4.10
4.00
0 50 100 150 200 250

Fig 6.1 Trend chart of Carbon % in Hot metal

Basicity of Slag
1.15
1.10
1.05
1.00
0.95
0 50 100 150 200 250

Fig 6.2 Trend chart of basicity of slag

Hot metal temperature

1520
1500
1480
1460
1440
1420
0 50 100 150 200 250

Fig 6.3 Trend chart of hot metal temperature

Blast volume
90000
85000
80000
75000
70000
0 50 100 150 200 250

Fig 6.4 Trend chart of blast volume

31
Chapter 6 Data analysis

Oxygen enrichment
2400

2300

2200

2100
0 50 100 150 200 250

Fig 6.5 Trend chart of Oxygen enrichment

RAFT
2400
2350
2300
2250
2200
2150
2100
0 50 100 150 200 250

Fig 6.6 Trend chart of RAFT

Sinter FeO
11.00
10.50
10.00
9.50
9.00
0 50 100 150 200 250

Fig 6.7 Trend chart of sinter FeO

DCI
400.00
350.00
300.00
250.00
200.00
0 50 100 150 200 250

Fig 6.8 Trend chart of DCI

32
Chapter 6 Data analysis

Carbon saturation
5.00

4.90

4.80

4.70

4.60
0 50 100 150 200 250

Fig 6.9 Trend chart of Carbon saturation

Slag Viscosity
0.45

0.40

0.35

0.30
0 50 100 150 200 250

Fig 6.10 Trend chart of viscosity

IDR
80
75
70
65
60
55
0 50 100 150 200 250

Fig 6.11 Trend chart of IDR

DR
45
40
35
30
25
20
0 50 100 150 200 250

Fig 6.12 Trend chart of DR

33
Chapter 6 Data analysis

CWI

0.9

0.7

0.5

0.3
0 50 100 150 200 250

Fig 6.13 Trend chart of CWI

Mn partition
3.000
2.500
2.000
1.500
1.000
0 50 100 150 200 250

Fig 6.14 Trend chart of Mn Partition

Permeability
1.5
1.3
1.1
0.9
0.7
0 50 100 150 200 250

Fig 6.15 Trend chart of permeability

CRI
25.0

24.5

24.0

23.5

23.0

22.5
0 50 100 150 200 250

Fig 6.16 Trend chart of CRI

34
Chapter 6 Data analysis

CSR
67.50
67.00
66.50
66.00
65.50
65.00
0 50 100 150 200 250

Fig 6.17 Trend chart of CSR

Nut coke rate

50
40
30
20
10
0
0 50 100 150 200 250

Fig 6.18 Trend chart of Nut coke rate

Coal Rate
200
150
100
50
0
0 50 100 150 200 250

Fig 6.19 Trend chart of Coal rate

Alkali in Slag
0.90
0.80
0.70
0.60
0.50
0 50 100 150 200 250

Fig 6.20 Trend chart of Alkali in slag

35
Chapter 6 Data analysis

6.4 RIST DIAGRAM

Rist diagram eliminates the mass balance (except C), dissolution of Carbon in hot
metal and oxides. Construction wise, Y axis depicts the O to Fe atomic balance and X axis
depicts the O to C atomic balance. The atomic ratio of O/Fe and O/C is important case of blast
furnace operation. At all the time Fe- reduction releases some amount of Oxygen to maintain
its molecular balance with respect to prevailing pressure and temperature. Carbon and oxygen
balance are described through the operation line of blast furnace.

The Fe-O-C equilibrium diagram [figure 6.13] is incorporated to identify the deviation
in blast operation by means of operation line. The point W and M are obtained only by
incorporating that diagram.

If there is shift in W point to W’, then FeO in sinter and Ƞco varies accordingly. This
will affect the process as well as affecting the carbon requirement for reaction.

The slope of the operation line indicates the amount of CO required for Fe reduction.

Fig 6.21 Fe-O-C equilibrium diagram

Y axis
Fe2O3 = 3/2 =1.5
Fe3O4 =4/3 =1.33
FeO =1/1 =1
Fe =0/1 =0

36
Chapter 6 Data analysis

X axis
CO2 =2/1 =2
CO =1/1 =1
C =0/1 =0
These are the axis lines in Rist diagram.

Point A: (XA, YA)

YA=1.5, XA=Ƞco + 1

Point B: (XB, YB)

YB= YA* % of DR, XB=1

Point C and D: tangent/ interception of the point A and B.

Fig 6.22 Rist diagram for BF-2

37
Chapter 6 Data analysis

Fig 6.23 Rist diagram for BF-1

Information gathered from Rist diagram [Fig 6.22 & 6.23]:

• Deviation between the W point and operational line is the stack efficiency of the
furnace.
• Point A shift occurs only by Ƞco.
• Point B shift occurs only by DR.
• Point A shifting indicates the amount of CO converted to CO2.
• Point B shifting Indicates about the blast rate, solid C used for Fe-Ore reduction and
C reacted with gangue and other oxides.
• Point C and E obtained only by point B. so, point B is the critical point in Rist
diagram.
• Point W is the distance between the CO to maximum Ƞco.
• Point M is the distance between converted minimum Ƞco to CO2.

38
Chapter 6 Data analysis

6.5 MULTIPLE REGRESSION ANALYSIS

Apart from the trend charts, MRA used for developing relation between C in hot metal
and influencing factor. All the MRA equations is compared with the present data for hot metal
C calculation. It is almost matching with the equation which is formed through MRA.

6.5.1 Blast furnace- 2

MRA 1: Regression Equation

Hot Metal C = 6.402 - 0.000011 blast volume - 0.001116 slag volume - 0.01314 LOI Ore
- 0.002474 Deadman Cleanliness Index

Table 6.4 regression analysis report MRA 1

Coefficients

Term Coef SE Coef T-Value P-Value VIF

Constant 6.402 0.137 46.80 0.000
blast volume -0.000011 0.000002 -7.01 0.000 1.03
slag volume -0.001116 0.000123 -9.07 0.000 1.02
LOI Ore -0.01314 0.00251 -5.24 0.000 1.03
Deadman Cleanliness Index -0.002474 0.000085 -28.99 0.000 1.01

Fig 6.24 MRA 1 (normal probability plot)

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Chapter 6 Data analysis

Fig 6.25 MRA 1(Histogram)

MRA 2: Regression Equation

Hot Metal C = -2.388 + 0.004674 Hot Metal temperature - 0.1720 Hot Metal Si
- 2.422 Hot Metal S

Table 6.5 regression analysis report for MRA 2

Coefficients

Term Coef SE Coef T-Value P-Value VIF

Constant -2.388 0.395 -6.04 0.000

Hot Metal temperature 0.004674 0.000264 17.69 0.000 1.29

Hot Metal Si -0.1720 0.0496 -3.47 0.001 1.19

Hot Metal S -2.422 0.708 -3.42 0.001 1.40

Fig 6.26 MRA 2 (normal probability plot)

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Chapter 6 Data analysis

Fig 6.27 MRA 2(Histogram)

6.5.2 Blast furnace -1

MRA 1: Regression Equation
Hot Metal C = 4.171 + 0.000018 B. V - 0.001605 DCI - 0.883 Viscosity

Table 6.6 regression analysis report for MRA 1

Coefficients

Term Coef SE Coef T-Value P-Value VIF

Constant 4.171 0.171 24.36 0.000

B. V 0.000018 0.000003 6.12 0.000 1.19

DCI -0.001605 0.000090 -17.89 0.000 1.04

Viscosity -0.883 0.159 -5.55 0.000 1.16

Fig 6.28 MRA 1 (normal probability plot)

41
Chapter 6 Data analysis

Fig 6.29 MRA 1(Histogram)

MRA 2: Regression Equation

Hot Metal C = 4.441 + 0.001285 F. R - 0.001600 DCI - 0.756 Viscosity

Table 6.7 regression analysis report for MRA 2

Coefficients

Term Coef SE Coef T-Value P-Value VIF

Constant 4.441 0.205 21.63 0.000
F. R 0.001285 0.000375 3.43 0.001 1.40

DCI -0.001600 0.000084 -19.16 0.000 1.48

Viscosity -0.756 0.147 -5.13 0.000 1.08

Fig 6.30 MRA 2 (normal probability plot)

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Chapter 6 Data analysis

Fig 6.31 MRA 2(Histogram)

6.6 COMPARISION OF DATA

Based on the statistical and technical study, the relationship between carbon
percentage and its influencing factors are tabulated below for BF#1 and BF#2, in table 6.8.

Table 6.8 Comparison of BF 1 ad BF 2 parameters

S. No Parameters Level of impact

BF 1 BF 2
1 % of C Decrease Decrease
2 Hot metal temperature (°c) Decrease Decrease
3 Blast volume Increase Increase
4 O2 enrichment Increase Increase
5 RAFT Decrease Decrease
6 Tuyere velocity Decrease Increase
7 CWI Decrease Decrease
8 PWI Increase Decrease
9 Slag volume Decrease Decrease
10 Total alkali Increase Increase
11 B2 Decrease Decrease

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Chapter 6 Data analysis

12 B3 Decrease Decrease
13 Flux input Decrease Increase
14 Ore MPS Decrease Increase
15 Sinter MPS Decrease Increase
16 Coke MPS Decrease Increase
17 Coke rate Increase Decrease
18 Coal rate Increase Increase
19 Nut coke rate Decrease Decrease
20 Permeability Increase Decrease
21 CSR Increase Increase
25 CO/CO2 Increase Increase
26 CO2/(CO+CO2) Decrease Decrease
27 BF gas generation Increase Increase
28 Mn partition Increase Increase
29 Slag flushing Decrease Decrease
30 Viscosity Decrease Increase
31 DCI Increase Increase
32 C saturation Decrease Decrease
34 Sinter FeO Increase Increase
35 Sinter basicity Increase Increase
36 IDR Decrease Decrease
37 DR Increase Increase

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Chapter 7 Conclusion

CHAPTER 7
CONCLUSION
All the furnace parameters are analysed to find out the cause for carbon pickup
variation in hot metal through statistical and technical study. Parameters such as Deadman
cleanliness Index, Ash content in the coal, Viscosity of the slag, tuyere velocity, CWI, Mn
Partition & slag sulphur & IDR & DR rate were found to be more significant parameters for
variation in hot metal carbon pickup in blast furnace. The following results were obtained from
data analysis.

1) DCI is mainly affected by parameters such as, coke strength, hearth erosion, scaffolds,
tapping practices. So, the inactive DCI directly affects the hot metal carbon content
along with drop in hot metal temperature. From the data, it is clearly indicated that
carbon pickup is affected by DCI. For having better carbon pickup, DCI shall be
optimum in the range of 220 to 300.
2) Ash content in the coal affects the carbon content in hot metal. Ash enters in the furnace
through pulverized coal injection. In tuyere region, conversion of Si from its oxide form
in the coal ash (SiO2+C → Si+ CO2) occurs and it requires solid carbon. This type of
reactions categorised as direct reductions. As the direct reduction increases, diffusivity
of carbon in hot metal and stack efficiency decreases. From the analysis, it is clearly
indicating that carbon pickup is less whenever the ash content in coal content increased
both in BF1 & BF2. The range of ash in coal should be 8.6 % to 9.4 %.
3) Slag viscosity is directly proportional to wettability of particles in bosh region. If slag
viscosity increases, contact between the slag and coke will be more and reaction rate
will be decreased between the iron ore and coke. It directly affects the carbon pickup in
hot metal. From the analysis, it shows that less carbon pickup whenever viscosity is
less. So that viscosity in the range of 0.3 – 0.35
4) Whenever, the tuyere velocity increases, carbon dissolution rate in hot metal will
increases. Additionally, the central coke charging will improve the carbon dissolution
rate by proper distribution of gas flow. The tuyere velocity is the major factor and it
shows in the range of 200 m/s to 220 m/s.
5) Reaction wise, formation of sulphides takes more carbon and forms CO. Commonly
MnS and CaS were present in the slag. So, the less Mn content in hot metal indicates
the more Mn in slag as MnO and MnS. This will induce more CO and reduce the carbon
content in hot metal. So that, the range of Sulphur in slag is maintained from 0.68 to
0.90%.

46
Chapter 7 Conclusion

6) Carbon saturation plays an important role, according to the Fe-C phase diagram. While
tapping, rapid decrease in the temperature was observed. Due to this the saturated
carbon content will come down to stable composition. More the carbon saturation, more
will be the carbon in hot metal. This is affected by presence of other elements (like, Si,
S, P, sulphides and oxides). Above 4.85 % of C saturation is required to obtain 4.40 %
C in hot metal
7) Reduction zones play major role in determining the furnace efficiency and utilization of
carbon. This will be understood better by indirect and direct reduction zones. The ideal
and more efficient furnace operation range is 75% (IDR) and 25% (DR). If any deviation
from this happens, it will cause high fuel rate and decreases the dissolution rate of
elements, especially carbon in hot metal. DR should be in the range of 25 to 40 % and
IDR in the range of 55 to 70 %.
8) Based on RIST diagram, temperature and efficiency of CO governs the carbon
requirement to reduce FeO to Fe. In order to get more carbon content in hot metal,
efficiency of CO should be high as well as the temperature. The CO utilization must be
above 45 %.
9) Blast furnace -1 operation parameter varies with blast furnace – 2 parameters such as,
tuyere velocity, PWI, the mean particle size of ore, flux, sinter and coke, coke rate,
permeability, CRI, H2, N2 and viscosity of slag. Due to these variable changes, BF-1
has minimum pickup range compared to BF-2.

To have better carbon pickup in hot metal, the above-mentioned optimum parameter
range shall be maintained consistently.

47
Chapter 8 Bibliography

CHAPTER 8
BIBLIOGRAPHY
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