PREPARED BY

TAYYAB TARIQ (2008-MET-04) TOUSEEF AMIN (2008-MET-12)

DEPARTMENT OF METALLURGICAL MATERIALS ENGINEERING.

UET, LAHORE

AND

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FERROUS METALLURGY
ORE
Naturally Occurring substance from which a metal can be extracted at a profit From a single ore more than one metal can be extracted.

ORE MINERAL
The mineral containing ore from which a metal c an be extracted at a profit The naturally occurring materials containing iron are known as minerals of iron and mineral deposits from which iron can be extracted at a profit (economically) are known as Iron-Ores.

GANGUE
Impurities associated with the ores

METHODS OF REMOVAL OF GANGUE

1) 2) 3) 4) 5) 6) Hand Picking(Sorting) Crushing, Grinding and Dressing Weathering (Removal of soluble impurities) Calcinations (Heating @ high temp to remove volatile materials) Roasting (Burning of ore in excess air) Smelting (Fusing the ore by heating it in a suitable furnace)

EXTRACTIVE METALLURGY
It is a branch of Metallurgy which is a study of extraction of me tal, purification and recycling

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Pyro metallurgical process

Hydro metallurgical process

The process which is used to In this process some salt or obtain metal from ore by leaching agent or solution is thermal treatment. used to obtain metal from ore

Electro metallurgical process The process of winning and refining of metal by the use of electricity

LEACHANT
Chemical that dissolves a particular metal

EXTRACTION OF METAL FROM ORE

Separating the ore from gangue. Driving away certain ingredients by heat short of fusion Fusing the ore one or more times in the presence of certain reagents called Fluxes which combine with the non-metallic impurities and allow the metal to settle down in an impure form. A metal thus obtained is further refined to be used.

RAW MATERIAL REQUIRED FOR MAKING IRON

a) b) c) d) Iron Ore Coking coal or Coke Fluxes ( CaCO3, Dolomite: CaCO3.MgCO3 ) Air

APPROXIMATE QUANTITIES FOR MAKING 1 TONS OF IRON

Material Iron Ore Coke Fluxes Quantity 1.7-1.8 0.7-0.8 0.4-0.5

IRON
Symbol: Fe Atomic Number: 56 Commercial Forms Pig Iron Wrought Iron Steel %age of Carbon 2.5-4.5 0.12-0.25 0.25-2.5

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ADVANTAGES AND DISADVANTAGES OF IRON

Advantages Enormous deposits are present Easy to reduce than Non-Ferrous metals Cheap metal Forms series of alloys Magnetic in nature Disadvantages Poor Corrosion resistance High density Poor conductor of heat and electricity as compared to Cu and Al -

CLASSIFICATION OF IRON ORES

a) b) c) d) Geological Classification Mineralogical Classification Impurities associated with Fe ore Appearance/Texture

GEOLOGICAL CLASSIFICATION
Sedimentary These mainly include SiO2 and iron ore in alternative bands. Iron is present in the form of stone In the form of powder (Blue Dust) Igneous These are derived from igneous material of volcanic origin & occur mainly as magnetite. Lateritic These are formed in conditions of alternating dry & wet seasons resulting in leaching away of SiO2 and alkalis from the mother-rock leaving behind mainly Fe-ore. Replacement The circulating water removes limestone (CaCO3) depositing iron carbonate in its place. Subsequently the surface weathering oxidizes part of the iron carbonate to Feoxide.

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MINERALOGICAL CLASSIFICATION OF IRON ORE

Minerological Classification

Magnetite

Limonite

Heamatite

Chloropal

Pyrite

Siderite

Liminite

Turgite

Geothite

Xanthosiderite

Limonite

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Properties Formula Common name %age of Fe Contribution Specific Gravity Appearance

Magnetite Fe3O4 Ferrosoferric oxide 72.5% 5% 5 Grey - Black

Limonite Heamatite mFe2O3.nH2O Fe2O3 Anhydrous Hydrous Ferric ferric oxide oxide 52.1366.31% 70% 40-60% Brown 5-6 Red Mostly in all rocks, Non magnetic due to **d/c < 1.2 Moderate Easy

Chloropal FeSiO3 Iron Silicate Decreases due to Dolomite* -

Pyrite FeS2 Iron Sulphide 4.95-5 Fool`s Gold Insoluble in water, Fool` Gold, Non magnet

Siderite FeCO3 Iron Carbonate Decreases due to Dolomite* -

Easy Detection

Magnetic in nature

High strength

High strength

Reduction

Difficut to break the Moderate ore *Dolomite is self fluxing agent, Diabasic MgCO 3.CaCO3 . **orbital/shell ratio Difficult

Difficut to break the ore

LIMONITE ORE TYPES

Limonite Sub-Ore Liminite Turgite Limonite Geothite Xanthosiderite Formula Fe2O3.3H2O 2Fe2O3.H2O 2Fe2O3.3H2O Fe2O3.H2O Fe2O3.2H2O

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CONCENTRATION OF IRON ORE

Concentration of Iron Ore

Mechanical Crystallization Chemical Precipitation

MECHANICAL CONCENTRATION OF IRON ORE

It involves mechanical concentration i.e. erosion of rocks containing iron ore by moving water. More the speed of the water more will be the erosion. It also depends on the gradient of water. So the corroded rock particles containing Fe ore moves with water, more dense the rock, earlier will it settle down and dense rock will travel with water. Hence due to this mechanical factor the concentration of Fe ore is different in different areas.

CHEMICAL CONCENTRATION OF IRON ORE

CRYSTALLIZATION Magma inside the earth crust contains different iron ores along with other mineral composites. The solidification rate of magma is very slow hence the material having similar composition will solidify or crystallize together. Hence due to this difference the concentration of Fe ore is different in different areas. PRECIPITATION This involves water falling on rocks or water in the form of steam blowing the rock. Chemical reactions take place on its surface and iron ores are separated from the rock and are deposited there. The chemical reaction or precipitation of iron ore depends on Speed of moving water Rate of the reaction Chemical nature of gangue

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IRON ORE DEPOSITS IN PAKISTAN

Dilband Nizampur Chiniot Pachinkoh Rajoa Langrial Kalah Bagh Chilgazi Dommel Nisar

Name of Deposit

Kalabagh (Punjab) Dilband (Balochistan) Nizampur (NWFP) Pachinkoh (Balochistan) Langrial (NWFP) Chilgazi (Balochistan) Chiniot (Punjab) Dommel Nizar (NWFP)

Distance from Karachi km 1200 800 1600 1750 1600 1150 1200 1900

Reserves

% of Fe

Ore Mineral

Methods of Mining

Million Ton 300 200 100 45 30 23 16 3

30-35 35-45 30-35 35-38 30-40 10-55 10-60 Upto 60

Silicates, Carbonates Oxide, Heamatite Heamatite Heamatite, Magnetite Silicates, Carbonates Magnetite Silicates, Carbonates Magnetite

Underground Open Cast Underground Underground Underground Underground Underground Underground

Which is better?

Have a look

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Dilband resources are better than all deposits of Pakistan (Fe ore deposits) and thus have a fair chance of development due to good accessibility, moderate grade (% of Fe), large reserves and open cast minebility. These deposits consist of Hematite and are low in P2O5; hence are better than many iron deposits of the world. Dilband Ore 35-45% Fe Low P2O5 Heamatite Ores from USA & Europe 5-35% Fe High P2O5 Heamatite & Limonite

Dilband d

VALUATION OF FE ORE
1. 2. 3. 4. Richness Location Composition of Gangue Procedure required before smelting

Richness % of Fe present in the ore, How much Fe is required, How much ore is required is dependent on % of Fe e.g. India requires 2 ton ore (55-60% Fe) to produce 1 ton Fe whereas Australia requires 1.5 ton of ore (68% of Fe) Location Hilly Area Geological Deep Valleys Geographical Mode of Transportation

Composition of Gangue Gangue material will affect the cost of the iron. If the amount of the gangue in the Fe ore is more then we have to add fluxes to separate gangue which will as a result increase the cost of production Some compounds in gangue Oxides, Carbonates, Sulphates, Na 2O, K2O, P2O5, As2O3 They are reduced in Blast furnace a. Totally b. Partially c. Non-reducible Totally Reduced in BF Phosphorous Arsenic The entire amount of P in the ore is Usually not present in Fe ore but if it is reduced and joins the pig iron. The present then following treatments are used presence of phosphorous affects the Prior Reduction properties of iron. Calcination (Volatilization)
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In general, the phosphorous content of an ore reduces the value of the ore. Phosphorous in iron causes Cold Shortness during rolling.

Roasting

Zn Pb Zinc in the iron ore does not pass into the Pb is reduced during Blast Furnace pig iron but it volatilizes during reduction operation, it settles at the bottom of the furnace due to its high specific These Zinc vapours penetrate into the gravity (SG). refractory material (lining) and affect its properties. Partially Reduced in Blast Furnace S, Mn, SiO2 Silica, compounds of manganese and sulphur are partially reduced in the blast furnace so Si, Mn and S join the pig iron. Amount of these depends on the nature of Fe ore and the operation of burning fuel. Non-Reducible It contains the oxides the oxides like Al2O3, MgO and Alkalis. These entirely stay with the slag during smelting. Al2O3 Alkali Its presence in the slag produces MgO, CaO react with Al2O3. Magnesium Aluminate and Calcium Alkalis affect the refractory lining. Aluminates. As a flux, they react with impurities o It increase melting point of slag. and make slag. o Decreases the viscosity of slag. If present in the ore they prove to be Al2O3 should be 5% in the slag. profitable (self fluxing). Because increasing it would increase the fluxes requirement. Treatments & Procedure required before Smelting Situation Treatment Comments Big Lumps Comminution Small Lumps Agglomeration Because otherwise, the oxygen/air blasts will blow away the small lumps. Carbonates Calcination Reducing to This will produce CO2 Oxides

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Raw Materials in Blast Furnace Fe, Metallurgical Coal, Fluxes Metallurgical coal Flux The coal which can be converted into They are added during smelting coke is called Coking coal/Metallurgical For bringing down the melting point, coal. softening point of gangue. In the absence of air (O2). To reduce viscosity of slag Why not use coal? Because coke has: To reduce the activity of some of its o Strength components to make them o Permeability stable/unstable. o Higher calorific value o Less volatile content (Higher fixed-C content) o Less moisture o Less heating requirement Coke should contain: o Volatile 2% o Ash 10% o Fixed Carbon 85% o P = 0.018-0.04% o S = 0.6-1.5% o S by 0.1% Coke requirement by 2%

SMELTING
Any metallurgical process in which metal in pure or crude form is separated by fusion from its impurities with which it may be chemically combined or physically mixed is called smelting.

SLAG
The molten oxide product of melting is known as Slag. It is formed by both gangue and flux.

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FORMULA FOR THE EVALUATION OF FLUX

It indicates that the quantity of SiO 2 should be less than MgO + CaO. In general CaCO3 content should not be less than 95%, SiO 2 should be less than 5%. Nearly 0.5 ton of CaCO 3 is needed for producing 1 ton of Fe.

THE BLAST FURNACE

Why Coke? Strong Less Ash S, P Quality control Size

FUEL-COKE

As the rank of coking coal decreases, its coking properties also diminish. Ideally Coal = 7% ash Less than 1% S About 5% P

COKE
It is a solid coherent residue achieved by heating coal in the absence of air.

FUNCTIONS OF COKE
Coke serves these major functions. 1. 2. 3. 4. It is a fuel Providing heat requirement for chemical reactants, melting of slag and metal. It produces and regenerates reducing gases for the reduction of Fe oxide. It provides an open permeable bed through which slag and metal passes down into the hearth and hot reducing gases pass outward.

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QUALITY OF COKE
It is related to the quantity of coal, its processing and subsequent carbonization process. In general the properties which determine the value of coke as a the blast furnace fuel are: a) b) c) d) e) Chemical composition Chemical reactivity Thermal Stability Size Abrasion resistance and Strength

Quality of coke Composition Chemically the useful component of coke is fixed carbon which is the fuel as well as the reducing agent in the blast furnace. the balance is made up of ash contents, volatile matters, other impurities. The inorganic residue left after burning it usually contains refractory oxides like silica, alumina etc. It also contains Sulphur & Phosphorous. Reactivity Defined as rate of reaction b/w coke and Oxygen and any other gases capable of reacting with coke e.g. C + O2 CO2 The rate of burning of coke controls the rate of production of the blast furnace. In general the rate of burning of coke is directly proportional to: i. Area of coke exposed ii. Temperature and Pressure iii. Affinity of coke to oxygen (it depends on the blending material used and the carbonization process adopted.) Thermal Stability During descent in the the blast furnace, the coke gets progressively heated; when the coke gets heated beyond the temperature at which it was made in the coke oven, the process of carbonization restarts and the coke begins to contract. The temperature gradient results in the contraction and expansion of coke stresses and its consequent tendency to degradation. So in order to achieve thermal stability, high carbonization temperature and uniform coke is used. Size Among all the qualities of good metallurgical coke the most important are its size and strength. The size range is known to affect the distribution of material inside the furnace and consequently the gas flow which has a direct bearing on the production rate. It was found that: a) If mean size of burden = 13mm then coke size 53mm b) This corresponds to an average coke to burden ratio: Coke : Burden 4 : 1 In general it has been suggested that the optimum coke size should be 3-5 times than that of burden.

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Abrasion resistance and strength During the transportation of coke in the the blast furnace different abrasion actions occur. In addition to this, coke has to withstand high temperature and nearly 20-25 meter tall burden lying over it, when it reaches the tuyere level. A coke that breaks down under these additions will adversely affect furnace permeability. It is an established practice to estimate the suitability of coke used in a the blast furnace in terms of its strength and abrasion resistance by measuring its shatter and abrasion indices.

SHATTER TEST (IMPACT RESISTANCE)

It consists of carefully dropping of sample of certain fixed weight of coke from a standard height on a standard quality floor. The shatter index is expressed as %age retained on various sieves of certain fixed sizes.

TUMBLER TEST (ABRASION RESISTANCE)

A standard weight of coke sample is part into a drum and rotating it for a fixed speed. The abrasion index is expressed as the %age of the material retained on various sieves.

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ALTERNATIVE FUELS

Charcoal It was used as alternative fuel to replace entirely the coke using small furnaces. The charcoal used should be strong and ferrous. The Proportion of Fe made by charcoal is practically negligible. Furnace height is to be lessened because it cannot bear the burden. Wood is converted into charcoal on heating. Formed Coke The solid fuel produced from non-coking lower rank coal is called formed coke. Only that formed coke that has proper physical and chemical properties can be used in the the blast furnace. Formed Coke Conventional Coke Cheaper Costly Lower manufacturing cost Higher manufacturing cost Continuous operation of the plant unlike Discontinuous manufacturing processes coke ovens Ferro Coke Fe + C A carbonized lump produced from a mixture of Fe bearing fines and non-metallurgical coal is known as ferro coke. The %age of Fe bearing fines may vary from a few %ages to 15-20%. It has all the necessary requirements for its use in the blast furnace. Advantages: Non-metallurgical coal is used indirectly in the blast furnace. The total fuel requirement reduces since certain proportion of pre-reduced Fe is already inside the ferro coke. Coke consumption is reduced in the blast furnace and productivity is increased. Conclusion The blast furnace cannot be run without a certain amount of coke in the charge. The efficiency of the blast furnace mainly depends on quality of coke used as fuel. It is therefore necessary to understand certain properties of coke and devise means to obtain these properties. Ferro coke and formed coke are being developed to substitute coke.

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MANUFACTURING OF FORMED COKE

Coking Coal Non-Coking Coal

Dryer

Pulverization

Kneading

Binder

Forming

Carbonization

Formed Coke

The formed coal is charged to the carbonization furnace where the coal passes through low temperature carbonizing zone and then it is heated @ 1000C. The heating rate is controlled so as the coal not to be generated, collapse and break caused by bulging and shrinking. The carbonized coke is cooled to 100 0C or lower temperature in the cooling zone before it is discharged from the furnace.

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DISTRIBUTION OF BURDEN IN BLAST FURNACE

Burden contains Fe ore, coke and flux. The blast furnace is essentially working on the counter current principle. The descending solid charge meets the current of ascending gases and reduction of Fe ore along with its progressive heating takes place during the passage. Of all the reactions taking place inside the blast furnace, the reduction of the Fe ore is the most important and the most difficult.

EFFICIENCY OF THE BLAST FURNACE (PRODUCTION RATE)

It is directly determined by 2 important factors I. Rate of reduction of Fe-ore II. Rate of heating of Burden The above two factors depend on the time of contact and exposed volume of charge to gas. The burden therefore inside the blast furnace should have uniform and good bulk permeability.

PERMEABILITY
The ability of the material to give way to the gases to pass is called permeability. Higher the permeability, greater the gasses will pass through it. Otherwise choking takes place. Permeability is necessary to reduce choking (resistance to flow of gases).

SHAPE AND SIZE

If the charge particles are of similar size then the burden would be automatically a uniformly permeable burden irrespective of the way of charging in the furnace. However, blast furnace charge consists of different sizes and shapes of coke and ore, therefore it is very difficult to distribute them inside the furnace. In general finer the particles less will be the permeability.

CHARGING MECHANISM
It consists of double bell charging mechanism. In this the materials are first charged in the small bell which is then lowered to allow the material to drop into the lower big bell during which the big bell remains closed. Then the small one is closed and the big bell is lowered to drop the charge inside the furnace. Such an arrangement practically prevents the furnace exhaust gases from escaping into the atmosphere while charging.

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ELEMENTS OF DISTRIBUTION
A mass of material consisting of shapes, size and densities that falls inside the blast furnace with various trajectories. In general dense, small and irregular particles remain subsequently where they fall, building ridges while light, large and smooth particles roll into troughs. As shown in the figure. This results in non-uniform permeability in the bed. The areas containing coarse particle have less segregation while the areas containing fine particles have high segregation. In general the coarse particles segregate in centre of the furnace shaft and the fine particles segregate at or near the wall depending upon the clearance between the bell and the furnace wall. As far as possible Fe ore should be present in area of maximum gas flow for efficient reduction. The size and system of charging are to be selected so as to have maximum utilization of gas subject to ensure smooth performance of blast furnace.

FACTORS AFFECTING DISTRIBUTION

The factors that affect the distribution of charge inside the blast furnace have been summarized below 1. Design of the blast furnace and charging device a) Angle and side of big bell b) Speed of lowering of big bell 2. Inconsistency in physical properties of charging material a) Size range of various charge materials b) Angle of repose of raw material and other physical characteristics of charge c) Density of charge 3. Level, system and sequence of charge program of revolving the distributor a) Distribution of charge on big bell b) Height of big bell from stock line i.e. the charge level in furnace throat c) Order and proportions of charging of various raw materials

ANGLE AND SIZE OF THE BIG BELL

Angle = 50-530 Normal gap between the bell and the furnace wall is usually between 800-1000 mm. Size of the bell depends upon the size of the throat of the blast furnace. If the clearance between the bell and furnace wall is more, the crest is located further away from wall. If the gap is less between big bell and the furnace wall, the fines accumulate near the wall and v-type contour is formed. The V and M type contour formations at the stock-line, which are also called hoppers depend upon the bell clearance from the wall The more is the gap/clearance the crest is located further away from the wall and the lesser is the gap the more fines accumulate nearer the wall.
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Too much or too narrow a gap between the bell corner and the throat wall tends to segregate the sizes and prevents normal distribution from being achieved Optimum ratio of throat to bell diameter results in optimum segregation of the burden In the figure given below, a) is the V-type contour hopper and b) M- type contour hopper

1) STOCK LINE LEVEL

The behavior of the particles immediately after their impact on the stock line controls the nature of segregation i.e. uniformity and permeability in the burden. This behavior depends on 1. Height of fall of material from the bell on the stock line 2. Angle of Big Bell The effect of height of the big bell above the stock line on the distribution of the charge is shown in the figure. The lowering of the stock line to the point where the trajectory of fall of material comes against the wall of the furnace results in the fine segregation near the wall. This is shown at point h1 and as the level goes up the crest moves away from the wall (at higher level say h2 and h3). If the angle of inclination becomes steeper then the hopper will form in the centre but if angle of inclination becomes deeper then the crust will move away from wall.

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2) SPEED OF LOWERING OF THE BIG BELL

1. The greater the speed of lowering of the big bell, the more the material will move toward the wall and thereby alter the contour as well as distribution. 2. V type contour is formed if the speed is greater; on the other hand, the slower the speed, more the material will move toward the centre and M type contour is formed. In short the speed of lowering of the big bell should be maximum as far as possible because slower speed tends to segregate the fines.

3) DENSITY OF CHARGED MATERIAL

Ore Flux Coke 5-6 g/cc 3-3.5 g/cc 1.5 g/cc

It means the rolling tendency of coke particles is more as compared to Fe ore. Since densities cannot be altered the size may be so chosen that their differential rolling tendencies are offset to some extent. In general the size of the Fe ore is 3-5 times lower than that of coke.

4) ANGLE OF REPOSE
When a multi-particle material is allowed to gently fall on a horizontal plane, it tends to form a conical heap. The base angle of this cone is called Angle of Repose. Factors affecting Angle of Repose: Particle size Surface characteristics Shape PSD (Particle Size Distribution) The smaller the Angle of Repose the more will be the homogeneity. How to overcome Angle of Repose? 1. 2. 3. 4. Eliminate the fines Minimize the moisture Remove the clay Dry the ore i.e. more dry ore (free from fines) more the angle of repose

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5) SIZE OF CHARGE PARTICLES

Increasing fines in the ore results in 1. Decrease in burden permeability 2. Increase in pressure drop 3. Decrease in reduction rate The size ranges in order and practice; More reducible Less reducible 10-37 mm 10-25 mm

6) DISTRIBUTION OF CHARGE ON THE BIG BELL

Three systems are used for charging charge to furnace stock 1. Bucket Old one 2. Belt conveyer Modern 3. Double bell Present (>80%) The distribution of charge on the big bell greatly affects the distribution in the furnace. For distributing the charge on the the big bell different operations have been used. The Mckee revolving distributor and its modifications are most widely used.

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MCKEE TOP OPERATION FOR CHARGING THE FURNACE

1) 2) 3) 4) Both bells closed; skip discharging the charge in the small belt hopper. The big bell closed. Small bell opened to allow the charge to fall in the big bell hopper. Small bell closed, big bell opened to allow the charge to be dropped inside the furnace. Both bells closed

MCKEE REVOLVING DISTRIBUTION

The charging is carried out in the sequence of CCOO and the hopper is rotated through 60 after every skip is dumped on the small bell which is lowered after every four (4) skips to dump the charge on the big bell. After eight (8) such charges have been charged i.e. when 32 skips are charged, the big bell is lowered to allow the whole charge to fall into the furnace. Advantage; Homogenous mixing of charge
4 skips After 8 times Small Bell (after each skip 600) Opened THE BIG BELL (32 skips) Opened Furnace

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ORDER OF CHARGING
Mozumdar emphasizes the role of order of charging in the furnace distribution as change in the system of the charging of raw material influences distribution and character of gas flow to an extent considerably more than changes of level of charging and size of the charge, it is therefore having all conditions similar on an average only 3.5% of the cases go to the credit of control of distribution of gas flow by changing the size of the charge and 85% controls due to change of system of charging. The charging sequence in relation to the level of charging and the size of the charge has to be adjusted so as to have maximum utilization of gas ensuring smooth performance of the furnace.

CHARGING SYSTEMS
4 charging systems are commonly used.

1. 2. 3. 4.

Cn Om Om Cn Cn Om Om Cn Cn Om Cn-1 (wide range of distribution of coke)

BURDEN PREPARATION-1 TREATMENT OF FE ORE

BURDEN QUALITY
In order to operate the blast furnace smoothly and for high production rate the burden should have following properties. Physical 1) A close size range with minimum of fines (PSD narrow) 2) Ability to withstand physical stresses 3) Non-decrepitating nature 4) Ability to withstand reducing conditions without breaking 5) Good bulk reducibility 6) Low swelling index during reduction 7) A high softening temperature with a narrow temperature range of fusion Chemical 1) A high %age of Iron and low gangue contents 2) A low %age of SiO2, Al2O3 etc 3) Proper overall chemistry of the burden to ensure clean slag and metal separation at minimum temperature.

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CRUSHING AND SIZE

The size of the Fe ore should not be too small or too large because; If Fe ore contains too much fine particles 1) Permeability decreases 2) Pressure drop inside the furnace increases (varying pressure of O2) 3) Reducibility decreases If too large then 1) Material remains unreduced 2) Demand of heat increases 3) The maximum ore size is based on; a) Ore chemistry b) Bulk reducibility c) Ore characteristics

Max. Size from run of mine = 100125mm We reduce it to = 40mm In any crushing process we can reduce the size to 4-6 times 1st stage 150-250mm (reduced) 2nd stage 27-55mm (reduced)

BENEFICIATION TECHNIQUES
Conversion of low grade Fe ore to high grade Fe ore 1) 2) 3) 4) 5) 6) 7) 8) Magnetic separation Gravity separation Froth floatation Electrostatic separation Magnetic roasting Low intensity magnetic separation Washing Calcination

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MAGNETIC SEPARATION
Magnetite can be easily separated at low intensity magnetic field as it is strongly magnetic. Weakly magnetic materials like hematite can be separated at high intensity magnetic field only. Dry method is suitable in the particle size +6mm and wet method is suitable if the particle size is -0.1mm. Magnetite can be separated at 1500 orested magnetic field intensity while hematite can be separated at 12000 orested. Usually ore is held on a rotating drum part of whose surface is magnetized. The non-magnetic tailings fall from the drum. A series of magnetic separators are used in active beneficiation.

GRAVITY SEPARATION
HEAVY MEDIA
The method is used when the particle size is 6-40mm. An artificial heavy medium is prepared by having ferro-silicon sand in a suspension in water such that the density lies in between that of the Fe oxide and the gangue. The Fe oxide concentrate sinks and the gangue overflows as tailing.

JIGGING
We use a perforated bottom on which ore particles are placed, the periodic impulses of water flow are subjected through the perforation; as a result heavy particles move down and are reduced as concentrate.

TABLING
It is suitable for sandy feeds. The feed moves over an inclined shaking table and is washed with a cross stream of water. Its operation cost is high and output is very small i.e. 1-2 tons/hour.

SPIRAL
This method is suitable for materials having particle size 0.1-1.5mm. In it the ore is washed down the spiral launder with a curved bottom. Fe mineral being heavier moves to the bottom of the curved track while the lighter tailings sling toward the outer rim. The output of individual spiral is very low. Therefore it is necessary to have no. of spirals.

FROTH FLOATATION
This method is based on the fact that surface property of some minerals can be temporarily altered to make it either hydrophobic (abhorrence from water) or hydrophilic (water loving). Hydrophobic minerals can be floated as froth if air is bubbled through a suspension of such minerals in water. Various reagents are used according to the surface characteristics of metallic minerals or gangue. Petroleum sulphonates, fatty acids and special oils etc are used to float iron oxide. Starch tends to float silicon and depress iron oxide. Even though floatation reagents are required in small amount but are costly so the overall cost of the process increases.

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ELECTROSTATIC SEPARATION
This involves the selective sorting of solid species by means of utilizing forces acting on the charged bodies in an electric field. The difference in the electrical conductivities between iron minerals and the gangue is made use of in separating the two with magnetic separation. The use of electrostatic separation in the final stages improves the purity of the product and overall concentration.

MAGNETIC ROASTING
Reduction Hematite 600-8000C, atm It is better than high intensity magnetic separation It is very easy to reduce hematite to magnetite under slightly reducing conditions at 600-800C and the ore is then easily separated by using low intensity magnetic field. Magnetite

WASHING
Washing means separation of particles based on their sizes by using such fluids in which finer particles get suspended and hence washed away while the large particles completely fail to get suspended and hence separated from the fines. Washing improves screening ability by removing the fine particles.

DRYING
Wet ores were initially being used by many operators from an economical point of view as the hot gases of the blast furnace have the capacity to wet the charge. But the problem which was faced was that the wet raw material cannot be screened efficiently so it is generally winded.

CALCINING
Fe is ultimately produced by reducing Fe oxide present in the ore. The use of OH, CO32 or sulphite type ores can be used for Fe making after calcining.

BLENDING
This involves mixing two or more types of material from two or more sources to obtain a uniform material of desired qualities over an extended period. The Fe ore blend may be made up of ore from different sources or it may also include materials such as coke breeze and CaCO3.

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AGGLOMERATION OF IRON ORE

The fines in the iron ores need to be agglomerated into lumps of suitable physical characteristics size/shape so it can be used in blast furnace. The techniques used are as: 1. 2. 3. 4. 5. Briqwetting Nodulising Extrusion Sintering Pelletising

BRIQWETTING
It essentially consists of pressing of ore fines with or without the binder into a block or briqwet of some suitable size and shape and then subjected it to a hardening process. Cement briqwetting is done with 1-5% cement as binder, press into blocks and harden in a tunnel kiln heated to about 13500C. Production is 1000t/day from a single plant. There are two types of briqwetting Cold briqwetting Hot briqwetting

COLD BRIQWETTING
It is produced by adding 10% cement and hardening them for several days like cement concrete.

HOT BRIQWETTING
It is done by pressing ore fines at 800-10500C under normal or slightly reducing conditions.

NODULISING
Fine ore concentrate and some carbonesous material like tar are passed through a rotary kiln which is slightly inclined to the horizontal. The temperature in the rotary kiln softens the ore, the speed of rotary kiln is 1-2rpm, length is 30-60m, diameter is 2m and diameter of sinter zone is 4m. the charge takes 1-2 hour in the kiln. This technique is replaced by sintering and pelletising.

EXTRUSION
It was used in 1950 on a small scale level. In this process moist ore with or without binder is fed into a chamber and then extruded from that chamber. The product obtained is cylindrical and is cut into a desired small size. The product is dried and fired before being used in blast furnace.

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SINTERING
It is a process of heating of mass of fine particles to the temperature little below the melting point for the purpose of agglomeration of fines into lumps.

PELLLETISING
The process consists of rolling of moist ore fines of less than 100 mesh size with or without a binder into pellets usually 7-20mm in size. These green pellets are dried and fired before charging to blast furnace.

SINTERING
It is a process of heating of mass of fine particles to the temperature little below the melting point for the purpose of agglomeration of fines into lumps. In other words the sintering means Casting without melting

PRINCIPLE OF SINTERING
Iron ore sintering is carried out by putting a mixture of iron ore mixed with solid fuel on a permeable grate. Coke breeze is normally used as fuel. The top layer of this bed is heated to a sintering temperature by a gas or an oil burner and air is drawn downward to the permeable grate with the help of exhaust blowers. The narrow combustion zone developed initially at the top layer that travels through the bed raising the temperature of the bed. The cold blast drawn through the bed that cools the already sintered layer and thereby gets itself heated. The heat contained in blast is utilized in drawing and preheating the lower layers in the bed. In the combustion zone the bonding takes place between the grains and the strong and porous aggregate is formed. The process is over when the combustion has reached the lowest layer of the bed. The sintered coke is then removed from the grate in hot condition or after partial cooling. It is broken, screen and cool to produce desired fraction. The undersized is recycled and oversized is fully cooled and send to the Blast Furnace. Ignition source

Charge hopper

Permeable grate

Bed

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QUALITY OF SINTERING
The main objective of sintering is to agglomerate of fines particles. The others are 1. Size of ore (specific size is required in order to do sintering) 2. Strong agglomeration with good bulk reduction that depends on nature of ore and sintering process 3. To remove the volatile like CO2, H2O, SO2 etc 4. Flux incorporation in the burden

PROCESS VARIABLES OF SINTERING

There are certain variables that affect the process of sintering which are as 1. Bed permeability as decided by the particle size, shape of the mixture and thickness of the bed. 2. Thickness of the bed 3. Total volume of air blast drawn through the bed during sintering 4. Rate of blast drawn through the bed during sintering 5. Amount and quality of fuel added in the charge 6. Amount and quality of moisture added in the charge 7. Nature of ore fines 8. Any non-uniformity in the bed composition or in the process of sintering During sintering heat exchange takes place between the solid charge and air blast that is drawn through the bed. At any time during sintering the air blast initially gets heated that is it cools the combustion zone and in turns heats the lower layer of the bed. It is therefore essentially a phenomenon of gas solid heat exchange. In order to carry out both the heating and cooling functions of gas phase affectively i.e to obtain a faster rate of heat exchange the heat capacity of the blast drawn through the bed should be maximum, it means that the volume of the air drawn through bed during sintering should be maximum. More permeable the bed, the more will be air blast drawn through it. More permeable bed however leads to loss of the strength in the resulting sinter. These two factors oppose each other and hence should be adjusted at the optimum.

TYPES OF SINTER
There are three types of sinter 1. Acid sinter 2. Fluxed sinter 3. Super fluxed sinter
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ACID SINTER
In this process there is no addition of flux during agglomeration of fines of sintering. Fluxes are added separately during reduction of iron ore in the blast furnace.

FLUXED SINTER
In this process the fluxes are added to make the basicity of the sinter equal to the basicity of slag in the blast furnace. Basicity of fluxed sinter= Basicity of slag in Blast Furnace

SUPER FLUXED SINTER

In this process the percentage of fluxes is added more than in fluxed sinter. The basicity of super fluxed sinter should be greater than the basicity of slag in the blast furnace.

MECHANISM OF SINTERING
COMBUSTION CALCINING DRY WET

ORE BED

TYPES OF BOND IN PARTICLES OR FINES

The particles or fines during sintering form a bond between them. There are two types of bonding exist between the particles which are 1. Solid state bonding 2. Slag or glass bonding

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SOLID STATE BONDING

In solid state bonding the particles either diffuse or recrystallize. The physical change occurs in the particles when they combined to form a bond. For example calcium carbonate heated at high temperature and pressure is converted into marble.

SLAG OR GLASS BONDING

In this slag fuses and acts as binder between the fines and developed a bond. The chemical composition changes during formation of bond. During chemical change iron ore fines convert into ferrite, spinal, silicate. (Spinal) MgAl2O4 . Hercynite (FeAl2O4). Jacabsite (MnFe2O4) Physical change occurs when time is large and temperature is low Chemical change occurs when time is short and temperature is high

During bonding the probability may be 1. No chemical change no physical change 2. No chemical change but change physically 3. Both chemical and physical change

RAW MATERIALS
There raw materials specification should be proper in order to do better sintering process. There are following raw materials specifications which are as Charge size Fuel content Moisture

CHARGE SIZE
If the particle size of the charge is fine then the contact area will increase and on the other hand permeability will decrease. So sintering process will be improper. In order to do better sintering the particle size of the charge should be coarse, so that gasses can pass through the bed. If we have less than 3mm fractions then above 6mm fractions along with are used.

FUEL CONTENT
Fuel content is used uniformly 6-8%. The percentage of fuel in the top layer of the bed should be greater as compared to the lower layer because the heating is started from the bottom of the bed and going upward.

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MOISTURE
Moisture controls the permeability of the bed. When moisture evaporates it produces porosity.

CONTROL OF SINTERING PROCESS

Sintering process is controlled by the following factors Input heat Ignition input source Moisture content (permeability control) Speed of grate/bed machine Bed height

BLAST FURNACE
It is a steel tank lined with a refractory material (bricks).

PURPOSE
The purpose of blast furnace is to reduce iron oxide into molten iron called as hot metal.

RAW MATERIALS
The raw materials required for the production of iron are: 1. Iron ore 2. Limestone (fluxes) 4. Hot 3. Coke blast of air

DIAGRAM

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EQUIPMENTS/PARTS OF BLAST FURNACE

The blast furnace consists of the following parts Foundation Stack column Hearth Bosh Charging facilities available

FOUNDATION
It is a massive steep reinforce concrete mass partially embedded below the ground level. It is sufficiently strong to stand the loaded furnace weight.

SKIP CAR (CONVEYOR )

The skip cars and in some cases conveyors are used to deliver blast furnace charge to the top of the furnace.

BOSH
The bosh is the inverted conical section. It has the maximum diameter.

RECEIVING HOPPER
The blast furnace charge is loaded into the receiving hoppers which in turn deliver the charge to the rotating distributor. The rotating distributor helps in assuming the uniform distribution of charge in furnace stack.

HEARTH
It is a crucible like vessel upon which the vertical shaft portion of the furnace sets. All the molten metal and slag collect in the hearth before being drain.

BELLS (LARGE AND SMALL)

The large and small bells are conical shaped devices that form a gas tight lock hopper. The hopper prevents the gas escaping from the furnace while it is being charge.

BUSTLE PIPES
It encircles the blast furnace and delivers the hot blast air from the blast line to furnace.

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TUYERES
The hot blast air is delivered to the furnace through water cooled opening called tuyeres. The tuyeres are located at the top of hearth.

STACK COLUMN
The stack is the upper portion of furnace where the charge is preheated.

METAL AND SLAG NOTCHES

The molten metal is removed from the hearth through the metal notch. The metal is placed into the transfer ladles, while the slag may be transferred through the slag pot.

PROCESSES
The production of iron in the blast furnace consists of the following steps which are as

INTRODUCTION OF THE CHARGE

The charge is introduced in the blast furnace through cup and cone arrangement.

INTRODUCTION OF HOT BLAST

Simultaneously hot blast of air is introduced in the furnace through tuyeres.

COMBUSTION OF COKE
Coke present in the charge burns in the hot air producing CO 2. C + O2 CO2

PRODUCTION OF CO (REDUCING AGENT)

The CO2 forms rise up reacts with C and produces CO. CO2 + C 2CO

REDUCTION OF HEMATITE (Fe2O3)

CO formed is a powerful reducing agent. It reduces hematite to iron. Fe2O3 Fe2O3 + + 3CO CO 2Fe + 3CO2

Fe3O4 + CO2

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Fe3O4 FeO

+ +

CO CO

FeO Fe

CO2

+ CO2

DECOMPOSITION OF LIMESTONE
Due to high-temperature limestone decomposes into lime and carbon dioxide. CaCO3 CaO + CO2

FORMATION OF SLAG
Calcium oxide reacts with silica and formed calcium silicate which is called as slag. The iron formed is collected at the bottom of the furnace and a slag formed a layer on it. The iron obtained from this method is called pig iron. It contains carbon as major impurity.

REFRACTORY MATERIALS
Materials that retain their shape and chemical identity at a very high temperature are called refractory materials. E.g. fire clay, Alumina, magnesia etc These materials withstand at high temperature without fusing.

CLASSIFICATIONS OF REFRACTORY MATERIALS

Refractory materials are classified on the basis of the following groups Based on refractory material Based on refractoriness Based on method manufacturing

CLASSIFICATIONS ON THE BASIS OF REFRACTORY MATERIAL

REFRACTORY MATERIALS

ACIDIC

BASIC

NEUTRAL

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Acidic refractries consist of acidic materials. They are not attacked by acidic materials but easily attacked by basic materials E.g. Silica, quartz, fire clay Basic refractries consist of basic materials. They are not attacked by basic materials but easily attacked by acidic materials. E.g. Magnesite, dolomite refractroies. Neutral refractories are made from weakly acidic and basic materials. They are not attacked by both acidic and basic materials. E.g. Graphite, chromite, zirconia refractories.

CLASSIFICATIONS ON THE BASIS OF REFRACTORINESS

According to the refractoriness, refractories are classified into four types.

REFRACTORY MATERIALS

LOW HEAT DUTY

MODERATE HEAT DUTY (1630-16700C)

HIGH HEAT DUTY (1670-17300C)

SUPER HEAT DUTY (Greater than 17360C)

(1520-16300C)

CLASSIFICATIONS ON THE BASIS OF METHOD MANUFACTURING

REFRACTROY MATERIALS

DRY PROCESS

FUSED CAST

HAND MOULDING

DRY PROCESS: This process includes crushing the materials and presses it in a die and produces the required shape. E.g. bricks refractory, tile refractory etc. FUSED CAST: The refined raw materials are heated at 1900-2500C in a electric arc furnace,until completely melted. The melted substance is poured into specific molds and left to solidify gradually, resulting in a fused cast refractory. E.g. Alumina mullite, zirconia etc.

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These refractroies have Poor spalling resistance Sudden expansion and contraction High erosion and abrasion strength HAND MOULDING: These refractroies are made from slurry materials. E.g. Gun type refractory, Spray type refractory.

PROPERTIES OF REFRACTORY MATERIALS

1-REFRACTORINESS
It is the ability of a material to withstand very high temperature without softening or deformation under particular service condition.

HOW TO MEASURE REFRACTORINESS

Since most of the refractories are mixtures of several metallic oxides, they dont have sharp melting points. So the refractoriness of a refractory is generally measured as the softening temperature and is expressed in terms of pyrometric cone equivalent (PCE).

PYROMETRIC CONE EQUIVALENT (PCE)

Pyrometric cone equivalent is the number which represents the softening temperature of a refractory specimen of standard dimension and composition.

OBJECTIVE OF PCE TEST

1. 2. 3. 4. To determine the softening temperature of a test refractory material To classify the refractoies To determine the purity of refractories To check whether the refractory can be used at a particular serving temperature

2-POROSITY
Porosity is defined as the ratio of its pore volume to bulk volume. Porosity is an important property of refractory materials because it affects many other characteristics like chemical stability, strength, abrasion resistance and thermal conductivity. It reduces the strength It reduces the resistance to abrasion It reduces the resistance to corrosion Highly porous refractory possess the thermal conductivity. This is due to presence of more air voids, which act as insulators, and hence it is used in furnace lining. High porous refractory reduces the thermal spalling. Gases and slag attack more easily
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3-THERMAL SPALLING
Thermal spalling is the property of cracking, breaking, peeling off a refractory material under high temperature. It is due to the following factors 1. Rapid change in temperature 2. Slag penetration

RAPID CHANGE IN TEMPERATURE

This causes uneven expansion and contraction within the mass of a refractory material and leads to development of uneven stresses and strains.

SLAG PENETRATION
This causes the variation in the co-efficient of thermal expansion and leads to spalling. Thermal spalling can be decreased by using high porosity, low co-efficient of expansion and good thermal conductivity refractory.

4-SLAG RESISTANCE
Slag attacks the refractory at high temperature and alters its composition by forming of certain compounds with the refractory material. A basic slag attacks acidic refractory and vice versa. Rate of slag attacks is accelerated because of following reason Defective joints and cracks in refractory material Rough and extra porous surface The movement of slag The rate of slag attack is reduced if refractory is dense and smooth surface.

5-ABRASION RESISTANCE
A refractory is subjected to wear when it comes in contact with the moving charge as in case of blast furnace. Descending charge material result in abrasion or wearing off refractory lining material

6-ERROSION RESISTANCE
It damages due to mechanical action occurs when metal or gas carrying dust and slag particles hit against the refractory lining resulting in chipping off of particles from the refractory

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SELECTION OF REFRACTORIES
The refractories are selected on the basis of the following factors 1. 2. 3. 4. 5. 6. 7. 8. Area of application Working temperature Extent of abrasion and impact Structural load of furnace Stress due to temperature gradient Chemical composition/furnace environment Heat transfer Cost concentration

SOME IMPORTANT CLASS OF REFRACTORY

FIRE CLAY
It is hydrated alumina silicate Al2O3.2SiO2.2H2O containing about 25-45% Al2O3 and 50-80% SiO2. The term fire bricks are referred to fire clay bricks. There crushing strength decreases with increasing temperature. Porosity varies from 8-24% depending on the temperature on which it is fired. Higher the porosity less will be the slag penetration and less will be the effect of sudden changes in temperature. It is used in the upper part of Blast Furnace.

SILICA REFRACTORY
Raw material SiO2 refractory are the various forms of natural deposits of SiO 2. For example quartz, ganister, sandstone, sand. One of the great difficulties of SiO 2 refractory is that SiO2 occurs at different allotropic forms which are stable at different temperature. Sudden changes in temperature causes fire crack in silica bricks and this causes disintegration or spalling.

HIGH ALUMINA REFRACTORY

They are not used extensively because they are very costly. As the general rule the refractoriness increases with increasing alumina content of alumina silicate refractory compare to fire clay refractory. It contains 45-95% alumina. High alumina refractory gives better service under severe condition due to High abrasion and erosion resistance High spalling resistance/slag Good volume stability High refractoriness

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CARBON /GRAPHITE REFRACTORY

Carbon occurs in nature both in amorphous and crystalline form. Graphite is crystalline form of carbon. In graphite carbon atoms are arranged in hexagonal structure. Graphite is infusible and stable at about 36000C. It is not attack by slag and is resistant to thermal shock. Graphite is less prone to oxidation compare to other amorphous form of carbon.

USES
1. Carbon bricks find more extensive use in lining bosh/hearth of Blast Furnace. 2. They are also used in furnaces where temperature is high and atomosphere is non oxidize 3. Due to the presence of reducing atomoshpere in Blast Furnace the life of carbon refractory is prolong 4. High thermal conductivity of carbon lining helps in easy temperature control in the lower part of Blast Furnace 5. Iron and slag runner are also lined with carbon

CERAMIC GRAPHITE REFRACTORY

They are used in steel making process due to their high resistance of spalling and inactive nature. MgO graphite refractory is used in ladle lining Alumina graphite refractory is used in nozzle, sliding gates

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MAJOR

CAUSES

OF

FAILURE

OF

BLAST

FURNACE REFRACTORY
There are following factors that cause the failure of blast furnace refractory Attacking of carbon mono oxide (CO) gas on the refractory Action of alkali vapours Action of other volatile matters Action of acidic and basic slag Abrasion of refractory by solid, liquid and gases Action of molten metals Condition of operation Blowing in procedure All these factors do not affect all the areas of blast furnace. One or more factors can affect at one area. For example in the stack, the lining has to stand with abrasion with solid burden and CO attack, while in bosh region lining has to stand high temperature, erosion, attack of molten acidic and basic slag. Similarly the hearth has to withstand the attack of molten metal and slag without breaking.

BLOWING IN
The process of starting a newly lined blast furnace is called blowing in. In general the operation involves the following main steps 1. Drying 2. Filling 3. Lightening

DRYING
The new lining of the furnace contains significant portion of moisture which must be completely removed before the temperature of the blast furnace raised. The operation is called drying in which the furnace is slowly heated. The slowly temperature is about 200 0C which is slowly increased to about 4250C. But furnace drying can be accomplished by Hot blast from stove Use of coke oven to generate and supply hot gasses Use of coke fire in the hearth In this process care must be taken to heat up and dry the furnace slowly to avoid cracks in the newly built or required parts.

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FILLING
The blast furnace is then filled with the start of charge with generally consist of coke and fluxes in the lower part and coke, flux and an increasing amount of ore in the upper part. So the fuel ratio is much larger than the furnace operation. It is so because we have to raise the temperature up to smelting temperature before the ore reaches to the bottom of the furnace. Once the smelting temperature is reached, the burden or proportion of ore is gradually increased as the furnace is operated until about two weeks it starts carrying the normal burden.

LIGHTENING
The most common method to light the blast furnace is by using the low volume hot blast of approximately 5500-6500C to ignite the coke in front of tuyers. The blast volume is increased every few hours and after about 24hour 40-50% of full blast is achieved. It is increased until the full blast is achieved that is 100%

OPERATION UNTIL REGULAR PRODUCTION

Soon after the furnace is lighted the slag begins to accumulate in the hearth and a little later the iron as well. As soon as the slag reaches about the level tuyers it is drawn off at the sinter notch and the operation continuous until sufficient iron has accumulated to tape. The first iron tape off is not of proper grade as it is at this time impossible to have such temperature and composition of slag as to produce iron of given grade. Within a few tapes however the furnace is usually brought up to the production of desired grade.

BLOWING OUT
The process of shutting down the blast furnace i.e. for relining is called blowing out. When a furnace is to be shut down or blown out the ore charge is gradually reduced and stopped. Flux and fuel are continued until all metal and slag are tapped out and flux is then discontinued. The fuel is gradually reduced and finally shut off and fired slowly burns out. The furnace must be allow to cool gradually before being emptied

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BLAST FURNACE PRODUCTS

The blast furnace products contain Pig iron Slag gasses

COMPOSITION OF PIG IRON

Pig iron is major product of blast furnace that contains the impurities carbon, silicon, manganese, sulphur and phosphorus. These impurities in the pig iron have the maximum range and depend on the burden chemistry of the charge.

Elements Carbon Silicon Manganese Phosphorus Sulphur

Percentage impurities 3.5-4.2% 0.5-2.5% 0.5-1.5% 0.04-2% 0.04-0.15%

If the sulphur contents are very high in the pig iron then it will create hot shortness during rolling, forging. This is because at high temperature sulphur reacts with iron and forms iron sulphide (FeS) that produces cracks. S, Si, P are not completely reduced in the blast furnace they should have the minimum percentage in the pig iron in order to make steel. Whatever is the phosphorus content in the burden; the whole of it is reduced and finally joins with molten metal. The presence of carbon in the pig iron is beneficial during its conversion to steel. Whereas the presence of phosphorus in pig iron is detrimental, and it adds to the cost of steel making. The contents of Si and S depends on the volume of slag its basicity and operating temperature furnace and burden chemistry of charge. These can therefore be varied within certain limits by adjusting the burden chemistry, fuel rate and those conditions will affect the temperature of the blast furnace. of the

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SULPHUR PROBLEM
It is difficult for steel maker to control the sulphur specification and S content of steel. S content of steel should not be more than 0.025-0.04. The process of steel making is capable of reducing the S contents up to 40% in the hot metal charge. Its mean in order to achieve the required percentage of S the hot metal should not contain more than maximum 0.06%. This can be achieved by using coke having maximum 0.6% S. if the S in the ore is around 1% then it is difficult to meet hot metal specification with respect to S contents. The sulphur problem is more severe when the continuous casting of steel is adopted. The finished molten steel should have no more than 0.025% S for continuous casting to operate smoothly. The coke use as a fuel in the blast furnace should low in sulphur. The cost of fuel is in inverse proportion to its S content. For economical reason therefore every efforts must be made to eliminate S and produce required quality of hot metal before putting it in the steel making furnace.

HOW TO CONTROL SULPHUR

Desulphurization inside the blast furnace can be affected in three different ways By having higher basicity By increasing the volume of slag By increasing the hearth temperature FeS + CaO + C CaS + FeO + CO

When the pig iron is tapped off from the blast furnace and is going to the steel making unit then during its rout the following process are run to remove either silicon or sulphur Basic burdening and desiliconization Acidic burdening and desulphurization

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BASIC BURDENING OF BLAST FURNACE

If the alumina (Al2O3) content in the burden is high the furnace hearth temperature has to be on the high side to keep the slag thick and free flowing. The basicity has also to be raised to obtain proper slag in this case. These conditions are more favorable for disiliconisation of metal inside the furnace. This can be fully used in obtaining pig iron containing less than 0.06% or preferably 0.04% sulphur. This often leads to high silicon contents of pig iron. Since silicon reduction is favored at high temperature. The pig iron is treated externally to remove silicon and produce hot metal of the specification required for steel making. This external treatment for elimination of silicon from molten iron is known as external disiliconisartion

REMOVAL OF SILICON
Silicon is removed externally by lancing the oxygen in the hot metal before carrying it in the steel unit. When oxygen is lanced then temperature of the hot metal increases due to the exothermic reaction. The temperature is maintained around 1400-14500C by adding iron oxide (Fe2O3) and calcium oxide (CaO) because at this temperature silicon reacts with oxygen and forms silica (SiO2) and go to the slag. If the temperature is very high means above 1450 0C then carbon has high tendency with oxygen. So decarburization takes place which we dont want. So we use mill scale (iron oxide) and lime as reagent to maintain temperature of molten iron in order to remove silicon. For dephosphorisation and desiliconisation of molten pig iron we have to provide sufficient amount of oxygen in order to oxidize all the amount of Si, P, Mn.

ACIDIC BURDENING OF BLAST FURNACE

The acidic burdening of blast furnace can be readily practiced if the total gangue in the ore and coke are salacious in nature. The slag basicity is also reduced since high basicity is no longer necessary. The furnace is often operated with basicity less than 1 that is the slag produced is acidic and for which the burden chemistry is adjusted with more acidic and less basic oxides. The net result is that the silicon content of the metal is low which is advantageous for subsequent basic process of steel making.

REMOVAL OF SULPHUR
A lance of oxygen is lowered into molten iron ladle and several kilogram powder of magnesium is added. Sulphur is reduced to magnesium sulphide in violent exothermic reaction

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DISPOSAL OF METAL
Major portion of molten iron is sent to steel making plant for its conversion to steel

DISPOSAL OF SLAG
Slag is carried in ladle to the slag dumping yard where it is tipped as waste material. Alternatively the slag granules are produced in a granulation plant where molten slag is poured in turbulent water. These granules are increasingly being used as construction material.

CONCLUSION
The main product of blast furnace is molten iron along with slag. The chemistry of metal is important and is adjusted as per the overall economy of steel production from ore. The chemistry of slag is adjusted to obtain efficiency operation of blast furnace. The waste product that is slag is also being put to some use.

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