Modern blast furnace ironmaking an introduction alibris. By improving process control of the blast furnace system operating conditions can be optimized, hot metal quality can be improved, and energy consumption and operatioal costs can be reduced. Methods of shutting down a blast furnace ispatguru. With the help of tmt measuring technology, process parameters can be gathered reliably and an optimized plant operation can be achieved by means of expert systems. The extraction of iron from its ore is a long and subdued process, that helps in separating the useful components from the waste materials such as slag. Automation and control in iron and steel industries jurgen heidepriem university of wuppertal, germany keywords. Developments in blast furnace process control at port kembla based on process fundamentals. The hot blast main enters into a doughnut shaped pipe. Chemistry of the ironmaking by blast furnace process ispatguru. The blast furnace process can be briefly described as follows.
Blast furnace valves ironmaking our activities site. The process level is a combination of model based and ai approaches. This article discusses the monitoring and control of a continuously operating. This book focuses on the control of the blast furnace process with respect to thermal control, gas flow control and casthouse operation. This book describes the principles of the blast furnace process and especially the control of the process.
The blast furnace process has auxiliary equipment associated with it. In case of the blastfurnace process automation the operational task of process conditions optimization shall preferably be implemented based on the algorithm of performance identification by operation statistics alongside with control and stabilization. The blast furnace gas bfg generated in the bf is cleaned through a series of steps primary cleaning at dust catchercyclone and secondary. Optimizing blast furnace operation to increase efficiency and. The blast furnace bf is the heart of the integrated iron and steel industry. Aug 04, 2011 the precise filling order is developed by the blast furnace operators to carefully control gas flow and chemical reactions inside the furnace. This guideline of safety is applicable to blast furnace dept.
Pdf developments in blast furnace process control at. Iron oxides, flux agents, and metallurgical coke are. Plans for an extended shutdown or interruption to furnace operation either for a breakdown, scheduled repair or because market conditions indicate a pause in production is desirable, may influence management to blow down a blast furnace. This concentrated ore is mixed with limestone caco 3 and coke and fed into the blast furnace from the top. A world class blast furnace operation demands the highest quality of raw materials, operation, and operators.
Calculation of blast furnace size is empirical in nature. The process fugitive control plan was revised in response to dtscs january 28, 2015 summary of violations. A model aided cowper process control has been implemented and commissioned during the installation of a new blast furnace control system for blast furnaces ii and iii of the klockner stahl gmbh in. Iron oxides, flux agents, and metallurgical coke are added to a skip car at the stock house. The blast furnace process in the hearth, refining of the liquid metal and final reducthe iron blast furnace is in principle a countercurrent tion and separation of the liquid slag and metal occur as. In the past, static calculation based on blackbox principles were used to predetennine some fundamental set points with limited feedback from the process. Expert systems controlling the iron making process in. Identification method of blastfurnace process parameters. To improve the technologies of iron smelting and solve the tasks of control of such. At the basic level, classical control approaches are used. The blast furnace bf is the most widely used ironmaking. Modern blast furnace ironmaking an introduction pdf. Blast furnace products and there use size of blast furnace design of blast furnace is evolved through experience. Sintering, blast furnace, oxygen blowing process, secondary metallurgy, continuous casting, electric arc furnace, hot rolling, cold rolling, processing lines.
Developments in blast furnace process control at port kembla based on process fundamentals robert j. Blast furnace process complexity in combination with growing demand on effectiveness and reducing environmental impact has necessitated a change in process control strategy. Nov 22, 20 blast furnace, co, reaction, slag, chemistry of the ironmaking by blast furnace process. In blast furnace the process is also known as counter current process as solid raw. The precise filling order is developed by the blast furnace operators to carefully control gas flow and chemical reactions inside the furnace. Several numerical approaches have been proposed in the literature to simulate the behavior of modern blast furnaces.
Jul 12, 2019 blast furnace and process description. Blast furnace process complexity in combination with growing demand on effectivity and reducing environmental impact has necessitated a change in process control strategy. A portion of this gas is fired in the blast furnace stoves to preheat the blast air, and the rest is used in other plant operations. Some examples of situations in which the use of the model is not recommended are the entrance of water in the blast furnace leaks in the staves or tuyeres and conditions with high process instability.
They are then used to help heat the air blast, required if blast furnace is to reach the high temperatures needed to produce molten iron. Despite this, there is actually no efficient method for evaluating quickly optimal operating parameters of a blast furnace as a function of the iron ore. Process monitoring by use of multivariate projection methods has received increasing attention as it can reduce the monitoring problem for richly instrumented industrial processes with many correlated variables. Ios press ebooks modern blast furnace ironmaking an. Developed control strategy for blast furnace control is based on black box principles. It is suitable for students of metallurgy as well as for blast furnace operators and management. For decades paul wurth has been designing and supplying specialised valves and bleeders for different applications in the blast furnace process. Logicalmathematical evaluation model of blastfurnace melting. Banking process in the blast furnace is adapted, since the procedure of banking is useful for short outages. Tmts blast furnace probe product range radar probe for burden level and burden descent speed. The formation of iron and steel the blast furnace 2. Blast furnace bf process control is one of the main contributor to the successful blast furnace operation and belongs to the key factors of its economic effectiveness.
There is an ongoing effort to reduce pig iron production cost which requires furnace productivity improvement, coke and. The principle of blast furnace operational technology and. Blast furnace simulation download ebook pdf, epub, tuebl, mobi. Stateoftheart computational fluid dynamics model optimizes fuel rate in. Blast furnaces differ from bloomeries and reverberatory furnaces in that in a blast furnace, flue gas is in direct contact with the ore and iron, allowing carbon monoxide to diffuse into the ore and reduce the iron oxide to elemental iron mixed with carbon. How a blast furnace works introduction the purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. Pdf the control of blast furnace top gas pressure by using. A high quality coke should be able to support a smooth descent of the blast furnace burden with.
The materials are charged into the blast furnace through two stages of conical bells 5 which seal in the gases and distribute the raw materials evenly around the circumference of the furnace throat. View enhanced pdf access article on wiley online library html view. This auxiliary equipment and the gaseous pathways inside a blast furnace process are shown in figure 2. Pelletizing a pellet plant contains a series of balling drums where the iron ore concentrate is formed into soft pellets, in much the same manner that one rolls a snowball, to make a pellet about the size of a marble between 14 and 12. Carbon monoxide explosion hazards in electric arc furnace. A blast furnace is a special type of furnace for smelting iron from ore. Modern expert process control systems continuously monitor certain parameters in the blast furnace and by using various process models including burden control, burden distribution, mass and energy. The burden charge consisting of iron oxide, flux and coke and it provides through the throat from the top of the furnace. As a starting point, the blast furnace is seen as a simple iron ore smelter, while gradually the physical, chemical and metallurgical background of the blast furnace process is clarified. Process simulation and control optimization of a blast. Blast furnace process control industrial efficiency. Describes the principles of the blast furnace process and especially the control of the process. T, burla person involved name designation and email.
The blast furnace operates as a countercurrent exchange process whereas a bloomery does. Multivariate process monitoring of an experimental blast. Dec 12, 20 several numerical approaches have been proposed in the literature to simulate the behavior of modern blast furnaces. Pdf information modeling system for blast furnace control.
Iron oxides can come to the blast furnace plant in the form of raw ore, pellets or. Blast furnace simulation download ebook pdf, epub, tuebl. Blast furnace simple english wikipedia, the free encyclopedia. May 05, 2015 plans for an extended shutdown or interruption to furnace operation either for a breakdown, scheduled repair or because market conditions indicate a pause in production is desirable, may influence management to blow down a blast furnace. Optimizing blast furnace operation to increase efficiency. At the same time, hot air called wind is blown inside the furnace. Review development of blast furnace burden distribution. Iron blast furnace is a vertical shaft, which is used to melt the iron ore and to produce hot metal by heat exchange and chemical reaction. Modern blast furnace ironmaking 3rd edition pdf ammedicine. Ore, limestone and carbon in the form of coke are put into the top of the blast furnace in layers.
Click download or read online button to get blast furnace simulation book now. They can be up to 60 metres 200 ft tall and 15 metres 49 ft in diameter. Example blast furnace safety incident noncyber attack related figure 3 and figure 4 show an example blast furnace to assist in visualizing. Blast furnace, a vertical shaft furnace that produces liquid metals by the reaction of a flow of air introduced under pressure into the bottom of the furnace with a mixture of metallic ore, coke, and flux fed into the top. Despite this, there is actually no efficient method for evaluating quickly optimal operating parameters of a blast furnace as a function of the iron ore composition. Introduction precondition for the dynamic process control was the blast furnace bf process control is one of the main contributor to the successful blast furnace operation and belongs to the key factors of its economic effectiveness. The sov required that the plan be revised to discuss repairs to the walls and roof of the containment building reverb furnace feed room and blast furnace feed room. A major advance in bf ironmaking has been the use of pulverized coal which partially replaces. Request pdf blast furnace process the objective of the blast furnace bf is to produce hot metal. Carbon monoxide explosion hazards in electric arc furnace steelmaking operations. Blast furnaces are used to produce pig iron from iron ore for subsequent. Once a blast furnace is started it will continuously run for four to ten years with only short stops to perform planned maintenance. In the blast furnaces bf liquid iron popularly termed as hot metal is produced by the process of reduction at high temperature from raw materials like iron ore, base mix, sinter, pellet, coke, fluxes limestone, quartzite, dolomite. Coke is the most important raw material fed into the blast furnace in terms of its effect on blast furnace operation and hot metal quality.
Control of blast furnace operation is often classified as poorly. In consequence, the main difference between manual operation and. Multivariate process monitoring of an experimental blast furnace. Automation and control in iron and steel industries. Existing results based on scalemodel, mechanism analysis and datadriven approaches are discussed in details in section 2, 3 and 4, respectively. Comparative performance evaluation of blast furnace. This work considers performance identification by operation statistics aimed to mathematical descriptions of blastfurnace processes. Developments in blast furnace process control at port kembla. As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. Blast furnace and process description chemical engineering. Step 2 the blast furnace the outer case is a water cooled steel casing that provides the main support for the 30 m high furnace.
An introduction 3rd the book focuses on the control of the blast furnace process with respect to thermal control, gas flow control and casthouse operation. Now there are nearly 700 blast furnace available in world. Liquid iron hot metal is produced in a blast furnace from the burden materials through a series of chemical reactions which are taking place at various levels in a blast furnace. Thermochemical model for blast furnace process control. Eafs are often used in steelmaking operations to produce carbon steels, as well. Developments in blast furnace process control at port. Measuring technology for blast furnace process control. The blast furnace is a tall, vertical shaft furnace which uses coke to reduce. The book focuses on the control of the blast furnace process with respect to thermal control, gas flow control and casthouse operation. Chemistry of the ironmaking by blast furnace process. Iron oxides can come to the blast furnace plant in the form of raw ore, pellets or sinter. It is in the blast furnace that extraction of iron occurs. Paul wurth designs its valves to meet and exceed the most severe operating conditions to be expected in blast furnace operation.
Special nozzles called tuyeres are used to put the air in the furnace. This site is like a library, use search box in the widget to get ebook that you want. The raw ore is removed from the earth and sized into pieces that range from 0. Extraction of iron metallurgy blast furnace and reactions. The iron ore concentrate is now mixed and ready for the pelletizing process. Together these control devices provide a clean fuel of less than 0. The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and preheated air is blown into the bottom. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. The variability of blast furnace process parameters and. Blast furnace iron making is the main method for modern steel production,the process of blast furnace is an important part. Overview of the steelmaking process pellets sinter limestone coke iron ore coal scrap blast furnace ironmaking converter steelmaking ladle refining blast furnace steelmaking coalnatural gas plate hotrolled bars rods tube rounds rails slab billet bloom hotrolled and coldrolled strip coils structural shapes.
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