BRIEF TECHNOLOGY OF BLAST FURNACE

OPERATION IN STEEL PLANT

Tata Steel Plant, Jamshedpur

Dipika Sinha
Personal Profile

EDUCATION
M. Tech(Chemical Engineering)
2016 NIT DURGAPUR (Durgapur)
B. Tech(Chemical Engineering)
2013
HIT (Haldia)

EXPERIENCE
4 1/2 years
Sr. Territory Manager, F&B CARREER
 Chemistry Teacher at Carmel Convent School, Durgapur
 Total 3 Yrs. And above inside TATA STEEL PLANT and
CONTACT INFO
Jamshedpur Continuous Annealing and Processing
------------------------------
Company Pvt. Ltd.(JCAPCPL) as Water Expert of Nalco
Email(Personal)
[email protected]
Water
 1 Year and Counting with Diversey India as Sr. Territory
--------------------------
Manager, West Division, Food & Beverage (F&B)
LINKEDIN
https://www.linkedin.com/in/dip LANGUAGES
ika-sinha-44541970/ English, Bengali, Hindi
--------------------------------
INTERESTS
Hometown: Durgapur
--------------------------------- Travelling, Sports, Blending my
Currently Located: Mumbai hands in Kitchen, Dancing
SAFETY: OUR TOP MOST PRIORITY
TATA STEEL PLANT: ORE TO COIL

Raw material & Iron Making Steel Making Finishing Mill Power System
Coke plant LD# 1 NBM PH# 3, 4, 5 & BPH

Pellet plant LD # 2 TSCR

LD # 3 HSM
H Blast Furnace
I Blast Furnace
WRM

4
MM
BLAST FURNACE CHARGE

1. Iron Ore--------------------------------------------

2. Coke--------------------
(fuel)

3. Limestone--------------------
(Keeps waste bits together)
BLAST FURNACE: THE PROCESS

Receives Ore as:

Sinter
Pellets
Lump Ore
Coke as Fuel/ Reductant
 Forms CO Reducing Gas
Limestone as Flux
Forms Slag with Impurities
Produces:
Hot Metal
Slag
BF Gas
BLAST FURNACE: THE PROCESS
BLAST FURNACE: REACTIONS

 Cast house and runner system:

refractory lined runners to separate
liquid iron and slag
 Reactions very Exothermic
 Temperatures +2000DegC
BLAST FURNACE
The Charge is fed in at the top
Bell Doors open (One at a time)
Coke burns & makes Carbon
Monoxide
The Carbon Monoxide mixes with the
Oxygen in the Iron Ore (leaving Iron)
The Molten Iron falls to the bottom of
the Furnace
The limestone joins with the impurities
to make Slag and floats on top of the
Molten Iron
The slag and the Molten Iron are
tapped off regularly
Slag, Ammonia, Light Oils and Coal
Tars are waste from the Furnace
They make raw materials for cements,
plastics and fertilisers.
BLAST FURNACE: STAVES & TUYERES

Cast iron staves have the advantage of lower costs

and increased structural integrity and protection
of the furnace shell when furnace refractories
have been worn away

1. Temperature Fluctuations - Widely varying

refractory temperatures will promote cracking and
spalling.
2. Heat Load - Temperatures exceeding what the
particular type of refractory was designed to handle will
cause cracking and spalling
 HOT BLAST STOVE

Chequers Combustion
Chamber

Chequers: refractory bricks to store

thermal energy
BLAST FURNACE - PERFORMANCE INDICATORS
 Maximum Furnace Campaign Life
 +20 years
 Refractory
 Cooling System components (Plates/Staves/Tuyeres)

Maximize Maintenance and Operational Costs

 Hot Blast Valve
 Tuyeres
 Staves and Plates

Furnace Availability
BLAST FURNACE : ISSUES
3 1

1. Stoves
2. Tuyeres
3. Staves
WATER AND GAS TREATMENTS

Bell Less Top

Gas Cleaning Plant
Sinter Coke Ex. Scrubber

Hot Blast Stoves

Stock House Gasholder

Dust
Catcher
Scrubber

Enrichment Gas
Combustion Air Slag, Hot Metal

Blower

Combustion Gas
WWTP-Open Cooling
Closed Cooling System (Waste Water Treatment
(Closed Loop Cooling Plant) Plant)
Ex. HEAT Ex. Ex. Launders, Clarifiers, etc.
BLAST FURNACE COOLING – IMPLICATIONS OF
POOR WATER TREATMENT

 PROBLEMS: Internal fouling and corrosion of critical blast furnace

equipment
 Staves/ plates
 Tuyeres/ Coolers
 Hot Blast Valves

Impact/ Consequence: Equipment Failures

 Safety
 Lost Production
 Poor Hot Metal Quality
 Reduced Furnace Campaign Life
 Reduced Asset/ Component Life
 Increased maintenance costs
 Highest energy costs
 SHELL COOLING: STAVES

In Blast Furnace, refractory cooling would take place through Copper and Cast iron
staves. The copper plate has a much higher heat-transfer coefficient (HTC) than the
cast iron stave and has a much lower tendency for fouling. The mild steel pipes in the
cast iron stave can quickly develop an insulating layer of iron oxide corrosion product
that would reduce heat flux and bring about reduced refractory cooling.
BLAST FURNACE IRON
The slag and the Molten Iron are tapped off
regularly
Special rail cars bring the Molten Iron away
The liquid iron typically flows into a channel
and indentations in a bed of sand
Once it cools, this metal is known
as pig iron.
PIG IRON is raw iron in an ingot form.
It is the result of smelting Iron Ore, Coke and Limestone in a blast furnace
It is a hard but brittle mix of iron (90% or more) and carbon (typically 4-5%),
manganese, sulphur, phosphorus, and silicon (roughly 3% in total)
The name is derived from the time when the iron ran into moulds. A row of
moulds was said to resemble a litter of suckling pigs, so the single ingots were
referred to as pigs.
Pig iron contains 4 percent to 5 percent
carbon and is so hard and brittle that it is
almost useless.
We do one of two things with pig iron:
You melt it, mix it with slag and hammer it to
eliminate most of the carbon (down to 0.3
percent) and create wrought iron.
Wrought iron is the stuff a blacksmith works
with to create tools, horseshoes and so on.
When you heat wrought iron, it is malleable,
bendable, weld able and very easy to work
with.
Or we can create steel.
BLAST FURNACE IRON  STEEL
The Iron that comes from the Blast Furnace
requires further treatment to produce Steel
This is done in:

1. The Bessemer Converter or

2. The Basic Oxygen furnace
At the Steel making factory, it is mixed with
recycled steel and other alloys to make new steel
Steel is iron that has most of the impurities
removed.
Steel also has a consistent concentration of carbon
throughout (0.5 percent to 1.5 percent).
Impurities like silica, phosphorous and sulphur
weaken steel tremendously, so they must be
eliminated.
The advantage of steel over iron is greatly
improved strength.
STEEL MAKING
1. Bessemer Process 2. Basic Oxygen Furnace
TO RECAP
THANK YOU