Molten iron is produced in a blast furnace by the following steps: 1. A blast of hot air is blown into the furnace from the bottom. Every hour or so the molten iron is removed and sent on for further processing. Exhibit Links. How Steel Is Made. What Is Iron? Mining Iron. It is also the diameter of the straight section or belly above the bosh. The blast furnace is used to extract iron from its ore.
The iron ore, coke and limestone are fed into the top and the hot air is blown into the bottom. This carbon dioxide will then react with more coke to form carbon monoxide. The carbon monoxide then reacts with the iron ore to extract the iron as molten iron.
The hot air with a force of 4. Because of the heat, coke chemically dissolves the raw materials. Blast furnace slag BFS is a by-product from iron production in blast furnaces, which are fed by a mixture of iron-ore, coke and limestone.
In the process, the iron ore is reduced to iron while all remaining materials form the slag, which is tapped off as a molten liquid and cooled. Which fuel is best suitable for blast furnace process? Explanation: Coke is best suitable for blast furnace process as it also acts as a reducing agent in smelting iron ore.
First calcination and roasting, the ferrous oxide is oxidised to ferric oxide. Then in blast furnace, smelting is done, where it is reduced to get iron. Carbon monoxide is the actual reducing agent of hematite in blast furnace. One of the important reactions in metallurgy is the reaction of hematite Fe 2 O 3 with carbon monoxide to yield metallic iron [30].
As an alternative to iron production in a blast furnace, direct-reduced iron DRI is produced by reducing iron ore using a mixture of hydrogen and carbon monoxide Reaction 5. The blast furnace at Redcar, which is one of the largest in Europe, has produced up to 11 tonnes per day 77 tonnes per week but is currently running at tonnes per day.
This is equivalent to all the iron needed for about 5 cars every minute. Because the furnace temperature is in the region of o C, the metal is produced in a molten state and this runs down to the base of the furnace. This oxide helps to remove some of the acidic impurities from the ore. The slag is collected after the denser iron has been run out of a tap hole near the bottom of the furnace.
The production of iron in a Blast Furnace is a continuous process. Once the taphole is drilled open, liquid iron and slag flow down a deep trench called a "trough" Set across and into the trough is a block of refractory, called a "skimmer", which has a small opening underneath it.
The hot metal flows through this skimmer opening, over the "iron dam" and down the "iron runners" Since the slag is less dense than iron, it floats on top of the iron, down the trough, hits the skimmer and is diverted into the "slag runners" The liquid slag flows into "slag pots" 25 or into slag pits not shown and the liquid iron flows into refractory lined "ladles" 26 known as torpedo cars or sub cars due to their shape.
When the liquids in the furnace are drained down to taphole level, some of the blast from the tuyeres causes the taphole to spit. This signals the end of the cast, so the "mudgun" 29 is swung into the iron notch. The mudgun cylinder, which was previously filled with a refractory clay, is actuated and the cylinder ram pushes clay into the iron notch stopping the flow of liquids. When the cast is complete, the iron ladles are taken to the steel shops for processing into steel and the slag is taken to the slag dump where it is processed into roadfill or railroad ballast.
The casthouse is then clean-up and readied for the next cast which may occur in 45 minutes to 2 hours. Modern, larger blast furnaces may have as many as four tapholes and two casthouses. Liquid levels above the tuyeres can burn the copper casting and damage the furnace lining.
The first blast furnaces appeared in the 14th Century and produced one ton per day. Blast furnace equipment is in continuous evolution and modern, giant furnaces produce 13, tons per day.
Even though equipment is improved and higher production rates can be achieved, the processes inside the blast furnace remain the same. Blast furnaces will survive into the millennium because the larger, efficient furnaces can produce hot metal at costs competitive with other iron making technologies. Ricketts, Ispat Inland, Inc.
Iron Fe. Silicon Si. Sulphur S. Manganese Mn. Phosphorus P. Titanium Ti. Carbon C.
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