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TRANSCRIPT
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Maarten Geerdes
Hisko Toxopeus
Cor van der Vliet
Modern
Blast Furnace
Ironmakingan introduction
With contributions from
Renard Chaigneau
Tim Vander
Jennifer Wise
Second Edition, 2009
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vii
Contents
Preface v
Contents vii
List ofSymbols and Abbreviations xi
Chapter I Introduction of the Blast Furnace Process 1
1.1 What is driving the furnace? 4
1.2 The equipment 6
1.3 Book overview 10
Chapter II The Blast Furnace: Contents and Gas Flow 11
2.1 The generation of gas and gas flow through the burden 11
2.2 Furnace efficiency 15
2.3 An example of gas flow and contents of a blast furnace 16
Chapter III The Ore Burden: Sinter, Pellets, Lump Ore 19
3.1 Introduction 19
3.2 Iron ore 20
3.3 Quality demands for the blast furnace burden 22
3.4 Sinter 26
3.5 Pellets 30
3.6 Lump ore 34
3.7 Interaction ofburden components 35
Chapter IV Coke 37
4.1 Introduction: function ofcoke in the blast furnace 37
4.2 Coal blends for coke making 38
4.3 Coke quality concept 39
4.4 Coke size distribution 43
4.5 Mechanical strength of coke 44
4.6 Overview of international quality parameters 46
ChapterV Injection of Coal, Oil and Gas 47
5.1 Coal injection: equipment 48
5.2 Coal specification for PCI 49
5.3 Coal injection in the tuyeres 51
5.4 Process control with pulverised coal injection 52
5.5 Circumferential symmetry of injection 56
5.6 Gas and oil injectants 57
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viii
ChapterVI Burden Calculation and Mass Balances 59
6.1 Introduction 59
6.2 Burden calculation: starting points 59
6.3 An example of a burden calculation 60
6.4 Process calculations: a simplified mass balance 61
ChapterVII The Process: Burden Descent and Gas Flow Control 67
7.1 Burden descent: where is voidage created? 67
7.2 Burden descent: system of vertical forces 69
7.3 Gas flow in the blast furnace 71
7.4 Fluidisation and channelling 78
7.5 Burden distribution 78
7.6 Coke layer 84
7.7 Ore layer thickness 85
7.8 Erratic burden descent and gas flow 88
7.9 Blast furnace instrumentation 90
7.10 Blast furnace dailyoperational control 90
Chapter VIII Blast Furnace Productivity and Efficiency 93
8.1 The raceway 93
8.2 Carbon and iron oxides 96
8.3 Temperature profile 104
8.4 What happens with the gas in the burden? 104
8.5 Oxygen and productivity 106
8.6 Use of metallic iron 107
8.7 How iron ore melts 107
8.8 Circumferential symmetry and direct reduction 112
Chapter IX Hot Metal and Slag 115
9.1 Hot metal and the steel plant 115
9.2 Hot metal composition 116
9.3 Silicon reduction 117
9.4 Hot metal sulphur 118
9.5 Slag 118
9.6 Hot metal andslag
interactions:
special situations 122
Chapter X Casthouse Operation 125
10.1 Objectives 125
10.2 Liquid iron and slag in the hearth 125
10.3 Removal of liquids through the taphole 127
10.4 Typical casting regimes 128
10.5 Taphole drill and clay gun 130
10.6 Hearth liquid level 131
10.7 Delayed casting 132
10.8 No slag casting 134
10.9 One-side casting 135
10.10 Not dry casts 137
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10.11 Defining a dry hearth 139
10.12 Oxygen lancing 139
10.13 Cast data recording 140
Chapter XI Special Situations 141
11.1 Fines in ore burden 141
11.2 Moisture input 143
11.3 Recirculating elements 144
11.4 Charging rate variability 145
11.5 Stops and start-ups 145
11.6 Blow-down 147
11.7 Blow-in from new 148
Glossary 151
Annex I Further Reading 153
Annex II References 154
Annex III Rules ofThumb 156
Annex IV Coke QualityTests 157
Index 161