EVOLUTION OF BLAST FURNACE TECHNOLOGY

THE FIRST BLAST FURNACE WAS BUILT IN GERMANY IN 1300 AD.

BY 1850, BF OF ABOUT 18.3 M HIGH AND HEARTH DIAMETER OF 2.4 M WERE BUILT TO PRODUCE 27 THM / DAY.

BY 1900, A TYPICAL BF TO PRODUCE 180 THM/DAY WAS BUILT.

NEXT 80 YEARS, SAW A MAJOR CHANGE IN SIZE AND CAPACITY OF BLAST FURNACES. A BF TO PRODUCE 1900 THM/DAY WAS BUILT IN 1950.

THE LARGEST BF OF THE WORLD HAVING A USEFUL VOLUME OF 5,580 CU.METRE AND HEARTH DIS OF 15.1 M WAS COMMISSIONED ON 14TH APR’1986 AT THE CHEREPOVETS STEEL PLANT OF FORMER USSR. THIS FURNACE CAN PRODUCE OVER 11000 THM/DAY.

THREE SMALLER BLAST FURNACE OF RSP WERE COMMISSIONED IN 1959, 1960 AND 1962 RESPECTIVELY TO PRODUCE 1000 THM /DAY. THE BIGGER FURNACE WAS COMMISSIONED IN 1967 TO PRODUCE 1500 THM /DAY.

OBJECTIVE OF BLAST FURNACE

PRODUCTPRODUCT HOT METAL FOR STEEL MELTING HOT METAL FOR STEEL MELTING SHOPSHOP

COMPOSITIONCOMPOSITION 94 % Fe94 % Fe

4.0 % C4.0 % C

0.8 % Si0.8 % Si

0.5 % Mn0.5 % Mn

0.20 % P0.20 % P

0.050 % S0.050 % S

1450145000 C H.M TEMP AT CAST HOUSE C H.M TEMP AT CAST HOUSE

BY-PRODUCTSBY-PRODUCTS LIQUID SLAG / GR. SLAGLIQUID SLAG / GR. SLAG

32 - 34 % SiO32 - 34 % SiO22

20 – 22 % Al20 – 22 % Al22OO33

28 – 30 % CaO28 – 30 % CaO

10 – 11 % MgO10 – 11 % MgO

1 % MAX FeO1 % MAX FeO

0.94 % BASICITY0.94 % BASICITY

BF GASBF GAS

22 – 24 % CO22 – 24 % CO

2 % H2 % H

CV - 850 K/CAL/MCV - 850 K/CAL/M33

16 – 18 % CO16 – 18 % CO22

56 - 58 % N56 - 58 % N

DUST < 8 Mg/MDUST < 8 Mg/M33

HISTORY OF BLAST FURNACE AT RSP

INSTALLED CAPACITY 1.0 MT OF HOT METAL

• BF - I, II, III – 1000 T / DAY IN 1960s 1.8 MT AFTER EXPANSION IN 1970s

• BF - I, II, III -- 1000 T / DAY• BF – IV -- 1500 T / DAY

2.0 MT AFTER MODERNISATION IN 1998s• BF – I, II, III -- 1200 T / DAY• BF – IV -- 1800 T / DAY

COMMISIONING DATES OF BLAST FURNACE BF-1 = 27.01.1959 LAST RELINING ON 01.11.2001 BF-2 = 12.01.1960 LAST RELINING ON 10.12.2002 BF-3 = 08.01.1962 LAST RELINING ON 09.09.1997 BF-4 = 03.07.1967 LAST RELINING ON 13.09.2005

• BF - IV -- 2200 T / DAY (AFTER

MODERNISATION IN 2005)

FURNACE PROPER

BF – I,II,III BF – IV

PROD. CAPACITY 1200 THM/DAY 2200 THM/DAY

USEFUL VOLUME 1139 M3 1658 M3

WORKING VOLUME 995 M3 1448 M3

HEARTH DIAMETERS

7.4 M 9.0 M

HEARTH VOLUME 129.10 M3 191.0 M

BOSH VOLUME 168.70 M3 227.0 M

NO. OF TUYERES 18 21

SIZE OF TUYERS 140 – 160 MM 140 –160 MM

NO. OF STOVES 3/FURNACE 3/FURNACE

BLAST TEMPERATURE

950oC 1000oC

BLAST VOLUME (MAX)

90,000 M3/HR.160,000 M3/HR.

CHARGING SYSTEMII,III : BLTI : BELL SYS. WITH MTA

BLT

IMPROVED REFRECTORYGRAPHITE45% Al2O3

+ 7500

+ 11300

1100

+ 14000 MODIFIED TUYERE STOCK

NORMAL CARBON

STACK COOLERS

OVER BURDEN PROBEFIXED THROAT ARMOUR

+ 35225

BLAST FURNACE

BLAST FURNACE IS A COUNTER CURRENT HEAT EXCHANGER

LIQUID METAL AND SLAG ARE COLLECTED AT HEARTH. TAPPINGS AT REGULAR INTERVALS ARE DONE TO EMPTY THE FURNACE.

HOT METAL IS SENT TO SMS

SLAG IS SENT TO SGP / INBA / DUMP

RAW MATERIAL BUNKERS

BLAST FURNACE

HIGH LINEWAGONSBELT

IRON ORESINTER (SCREENED AT BF)COKE (SCREENDED AT BFLIME STONE / LD SLAGMANGANESE OREQUARTZITE

STO

VE

SCOLD BLAST FROM TURBO BLOWER

HOT BLAST

THROUGH SKIP

FLOW DIAGRAM OF BLAST FURNACE PROCESS

GAS CLEANING

PLANT

CLEAN GAS

TO OTHER CUSTOMERS

TO STOVE FOR HEATING

HOT METALTAP HOLE

SLAG

BF RAW GAS

SLAG GRANULATION PLANT

INBA CAST HOUSE GRANULATION

S M S - II

S M S - I

PIG CASTING MACHINE

MATERIAL BALANCE FOR 1 T OF IRON

BLAST FURNACE

AIR 2.42 T

SINTER 1.25 T+ ORE 0.45 T

LDS/LS 0.005 T

COKE 0.600 T

GAS 3.615 T

DUST 0.045 T

PIG IRON 1.0 T

SLAG 0.400 T

INPUT OUTPUT

QTZ. 0.001 T

RAW MATERIALS FOR BLAST FURNACES

MATERIALSMATERIALS SOURCESOURCE

IRON OREIRON ORE BARSUAN, KALTA, MEGHATABURU, BARSUAN, KALTA, MEGHATABURU, KIRIBURU, PURCHASED FROM OMC KIRIBURU, PURCHASED FROM OMC etc.THROUGH OBBPetc.THROUGH OBBP

SINTERSINTER SP – I & SP – IISP – I & SP – II

LIME STONELIME STONE PURNAPANI, BIRMITRAPUR and PURNAPANI, BIRMITRAPUR and PURCHASED FROM OUTSIDEPURCHASED FROM OUTSIDE

Mn OREMn ORE ROXY, BARAJAMDA, ROXY, BARAJAMDA, NAGPUR( PURCHASED ) NAGPUR( PURCHASED )

QUARTZITEQUARTZITE PURCHASEDPURCHASED

LD SLAGLD SLAG SMSSMS

COKECOKE COKE OVENS (COAL FROM DUGDA, COKE OVENS (COAL FROM DUGDA, BHOJUDIH, KARGALI, RAJRAPPA and BHOJUDIH, KARGALI, RAJRAPPA and Imported coal)Imported coal)

NUT COKENUT COKE COKE OVENS THROUGH SINTERCOKE OVENS THROUGH SINTER

PIG IRON CHIPSPIG IRON CHIPS PIG CASTING M/C SHOPPIG CASTING M/C SHOP

RAW-MATERIAL COMPOSITION NORMS

COKECOKE ASHASH : : 16 -1816 -18 0.5 0.5 CARBONCARBON : : 82 %82 %VOLATILE MATTER, VM :VOLATILE MATTER, VM : 0.9 %0.9 %GROSS MOISTURE .GM :GROSS MOISTURE .GM : 4.0 % 4.0 % SULPHURSULPHUR : : 1 %1 %MICUM -10mmMICUM -10mm : : 8 % MAX.8 % MAX.MICUM +40mmMICUM +40mm : : 80 % MIN.80 % MIN.HEAT VALUE HEAT VALUE : : 6500 Kcal 6500 Kcal /Kg/KgSIZE RANGESIZE RANGE : : 20 – 40 mm20 – 40 mm

SINTERSINTER FeFe :: 55 % 55 % 1 % 1 %FeOFeO :: 10 % MAX.10 % MAX.SiOSiO22 :: 4 TO 5 %4 TO 5 %Al2O3 : 2.5% MAXAl2O3 : 2.5% MAXCaOCaO :: 10.5 % 10.5 % 0.5 % 0.5 %MgOMgO :: 3.0 % 3.0 % 0.5 % 0.5 %-5mm-5mm :: 10 % MAX.10 % MAX.CaO/ SiOCaO/ SiO22 :: 2.8 TO 3.02.8 TO 3.0AlAl22OO33 / SiO / SiO22 :: 0.5 TO 0.60.5 TO 0.6SIZE RANGESIZE RANGE :: +5 – +25 mm+5 – +25 mm

RAW-MATERIAL COMPOSITION NORMS

BARSUA BARSUA OREORE

FeFe : 63 % MIN. (Fe : 63 % MIN. (Fe22OO33 = 86- = 86-87%)87%)AlAl22OO33 : 2.5 % MAX. SIZE 20 – 40 mm : 2.5 % MAX. SIZE 20 – 40 mmSiOSiO22 : 1.5 % : 1.5 % 0.5 % 0.5 %-10 mm : 10% MAX.-10 mm : 10% MAX.

KALTA OREKALTA ORE FeFe : : 64 % MIN.64 % MIN. SIZE 20 – 40 mmSIZE 20 – 40 mmAlAl22OO33 : : 2.5 % MAX.2.5 % MAX.SiOSiO22 : : 1.5 % 1.5 % 0.5 % 0.5 %-10 mm :-10 mm : 10 % MAX.10 % MAX.

LIME LIME STONE STONE

TITI : : 9 % 9 % 1% 1% SIZE 20 – 40 mmSIZE 20 – 40 mmCaOCaO : : 45 % 45 % 1% 1%-25mm :-25mm : 10 % MAX.10 % MAX.+50mm :+50mm : 10 % MAX.10 % MAX.

MN ORE MN ORE Fe : 24 % Fe : 24 % 1 % 1 % SIZE 10mm TO 50 SIZE 10mm TO 50 mm mm Mn : 26 % Mn : 26 % 1 % 1 % MnOMnO2 2 = Pyrolusite, = Pyrolusite, max.max.P : 0.15 % P : 0.15 % MnMn22OO33= Braunits = Braunits LD SLAG LD SLAG CaOCaO :: 40 – 45 %40 – 45 % SIZE 20 – 40 mmSIZE 20 – 40 mmMgOMgO :: 6 – 7 %6 – 7 %PP22OO55 :: 2 % MAX.2 % MAX.

QUARTZITE QUARTZITE SiOSiO22 :: 99 % MIN99 % MIN SIZE 20 – 40 mm SIZE 20 – 40 mm

OUTPUT NORMS

HOT METALHOT METAL Si 0.8 - 1.0 %Si 0.8 - 1.0 %

S 0.045 - 0.05 %S 0.045 - 0.05 %

TEMP 1450TEMP 14500 0 C AT CAST HOUSEC AT CAST HOUSE

SLAG SLAG CaOCaO 3232 - 34 %- 34 %

SiOSiO22 3030 -- 35 %35 %

AlAl22OO33 2020 -- 22 %22 %

MgOMgO 1010 -- 11 %11 %

MnOMnO 2 % MAX.2 % MAX.

FeOFeO 1 % MAX.1 % MAX.

SS 1 % MAX.1 % MAX.

BF GASBF GAS CVCV + + 850 K.cal / Nm850 K.cal / Nm33

DUST CONTENTDUST CONTENT << 8 MG / Nm8 MG / Nm33

OPERATING PARAMETERS

parametersparameters BFs – I, II ,III BF – IV

BLAST PRESSURE 1.15 KG/CM2 2 KG/CM2

0.8 HTP

BLAST VOLUME 90,000 Nm3/hr. 160,000 Nm3/hr.

BLAST TEMPERATURE 950 DEG C 1000 DEG C

BLAST MOISTURE 1.5 – 2 T/HR 2 – 4 T/HR

STOCK LEVEL 1.0 M 0.5 M

% Sinter in Burden 70.0 72.0

Fe / C 2.0 2.0

TOP GAS TEMPERATURE

1500 C 1500 C

TOP GAS CO 22 - 24 % 22 - 24 %

TOP GAS CO2 16 – 18 % 16 – 18 %

BFs – I, II ,III BF – IV

HOT METAL “Si” 0.80 – 1.00 0.80 – 1.00

HOT METAL “S” 0.045 - 0.050 0.045 - 0.050

HOT METAL TEMPERATURE

14300 C 14600 C

SLAG RATE 400 Kg/THM 400 Kg/THM

SLAG BASICITY 0.95 0.05 0.95 0.05

NO. OF CAST / DAY 9 9

COKE RATE 570 Kg/THM 570 Kg/THM

DUST RATE 8-10 Kg/THM 3-5 Kg/THM

OPERATING PARAMETERS

ROLE OF COKE

ACTS AS A FUEL

ACTS AS A REDUCING AGENT

SUPPORTS THE BURDEN

PROVIDES PERMEABILITY IN THE BURDEN COLUMN

CROWN RINGCONE

THROAT

BELLY

HOT METAL, 13200 C

SLAG, 14200 C

TUYERE ZONE, 16000 C

FUSION ZONE1200 – 16000 C

LOWER REDUCTION ZONE900 – 12000 C

UPPER REDUCTION ZONE300 – 9000 C

PRE-HEATING ZONE150 – 3000 C

TUYERE

BOSH

TAP HOLE

SLAG BIGINS TO FORM

PIG IRON BIGINS MELTING

COKE BURNS

SLAG FORMATION ENDS

MOISTURE REMOVAL

REDUCTION OF IRON

BREAK UP OF CaCO3

REACTIONS IN BLAST FURNACES VOLATISATION IN TOP ZONE

DE-COMPOSITION OF HYDRATES OF IRON AND ALUMINIUM AT 3000 TO 4000 C. THE RELEASED H2O ABOVE 4000 C REST WITH CO AS H2 + CO CO2 + H2 (WATER GAS)

CARBON DEPOSITION REACTION AT 4500 – 6000 C [ 2CO = CO2 + C + 41.2 K.CAL.)

THE REDUCTION REACTIONS AT 700 – 9000 C3 Fe2O3 + CO = 2 Fe3O4 + CO2 + 10.33 K.CALFe3O4 + CO = 3FeO + CO2 – 8.75 K.CALFeO + CO = Fe + CO2 + 3.99 K.CAL

DECOMPOSITION OF CARBONATES AT 900 – 11000 C [ CaCO3 CaO + CO2 – X K.CAL]

METALLOID REACTIONS

COMBUSTION ZONE REACTIONS

SLAG METAL REACTION

DIRECT REDUCTION AND MELTING ZONE SLAG AND IRON

FeO + CO = Fe + CO2

CaCO3 = CaO + CO2

CO2 + C = 2 COMnO + C = Mn + COP2O5 + 5C = 2P + 5COSiO2 + 2C = Si + 2COS+ CaO + C = CaS + CO

IND

IRE

CT

RE

DU

CT

ION

ZO

NE

OF

WU

ST

ITE

IND

IRE

CT

RE

DU

CT

ION

ZO

NE

TH

ER

MA

L R

ES

ER

VE

ZO

NE

FeO + CO = Fe + CO2

+UNREDUCED FeO

INACTIVE ZONE

Fe3O4 + CO = 3FeO + CO2

3Fe2O3 + CO = 2Fe3O4 + CO2

GAS

SOLIDS

PR

EH

EA

TIN

G

ZO

NE

TOP GAS 100 = 2500 C10 – 20 % CO2 + 20 – 30% CO + REST N2

ORE

COKE

GRANULAR ZONE

ACTIVE COKE ZONE

STAGNANT COKE ZONE

SLAG

METALHEARTH

RACEWAY

PRINCIPLES OF IRON MAKING

COKE BURNING SHOULD BE FAST

BURDEN MATERIAL SHOULD HAVE SUFFICIENT BED PERMEABILITY , OTHERWISE HANGING WILL OCCUR

GANGUE MATERIALS SHOULD BE AS LOW AS POSSIBILE

FLUCTUATIONS OF BLAST PRESSURE, BLAST VOLUME & FINES PERCENTAGE SHOULD BE LOW SO THAT THE FURNACE BEHAVES SYSTEMATICALLY .

SLAG FLUIDITY MUST BE SUCH THAT IT FLOWS EASILY

LOCAL OVERHEATING IS TO BE MINIMISED

PRINCIPLES OF IRON MAKING

OTHERS

• Si & S ARE NOT DESIRABLE IN HM. “Si” CAUSES SLOPING IN L.D. CONVERTER. IF RAFT IS MORE SiO2 GET REDUCED AND METAL HAS HIGH “Si” & COKE RATE HIGHER. IT TEMP. IS LOW “S” IS HIGH IN HOT METAL FLUIDITY WILL BE LOW.

• INCREASING SLAG BASACITY LOWER THE “SI” IN HM AS CaO COMBINES WITH SiO2 TO FORM COMPLEX COMPOUNDS WHICH DO NOT GET REDUCED . THE “S” IN HM IS LOWERED AS CaO COMBINES WITH MnS OR FeS IS FORM CaS.

• INCREASE IN MNO IN SLAG LOWERS “SI” IN HM AS MNO COMBINES WITH SiO2 TO FORM COMPLEX COMPOUNDS WHICH DO NOT GET REDUCED. THE “S” IN HM IS LOWERED.

• INCREASE IN SLAG FLUDITY LOWERS THE “S” IN HM . THE AL2O3 IN SLAG SHOULD BE 20 TO 24% FOR OPTIMAL.

ESSENTIALS OF GOOD BF OPERATION

SCREENED AND SIZED RAW MATERIAL

CONSISTENCY IN ALL RAW MATERIAL SUPPLY & QUALITY

MAINTAINING THE FURNACE STOCK LEVEL

PROPER CHARGE DISTRIBUTION

FOLLOW SPECIFIED OPERATING PARAMETERS VIZ. ADHERENCE TO SOPS & SMPS

ADHERENCE TO CASTING SCHEDULE

GOOD CAST HOUSE PRACTIVE

ASSURED OFF TAKE OF HOT METAL

REGULAR DRYING OF DUST CATCHER

MAINTAIN GOOD LADLE HEALTH

DIFFERENT UNITS OF BLAST FURNACE DEPTT.

HIGH LINES, STOCK HOUSE & CHARGING SECTION

FURNACE PROPER

GAS CLEANING PLANT

PIG CASTING M/C & LADLE REPAIR SHOP

SLAG POT HANDLING UNIT & SLAG DUMPING

INBA CAST HOUSE SLAG GRANULATION PLANT ATTACHED TO BF – 1 & 4.

DE-SULPHERISATION PLANT

WORK SHOP

PUG MILL

FUNCTIONS OF DIFFERENT UNITS

CHARGING SECTION• MATERIAL PROCUREMENT• STORAGE & STOCK LEVEL CONTROL• CHARGING

FURNACE & STOVES• REDUCTION OF IRON ORE• FORMATION OF LIQUID METAL AND FLUID

SLAG• REGULAR HEARTH DRAINAGE• MAINTAIN METAL & SLAG CHEMISTRY &

TEMP.GAS CLEANING PLANT• CLEAN BF GAS• MAINTAIN LINE PRESSURE OF CLEANED BF

GAS• SUPPLY COOLING WATER FOR BLAST

FURNACESPIG CASTING M/C• PROVIDE EMERGENCY OUTLET OF HOT

METAL IN CASE OF OFFTAKE PROBLEM

• CAST OFF GRADE HOT METAL INTO PIGS

LADLE REPAIR SHOPS• CLEANING OF LADLES• MINOR REPAIRS OF LADLES• RELINING OF LADLES

FUNCTIONS OF DIFFERENT UNITS

SLAG POT HANDLING UNIT• TRANSPORT OF SLAG TO SGP & SLAG DUMP• MAINTAIN REQUIRED FLEET OF SLAG POTS

SLAG DUMP• SUPPLY CLEAN SLAG POTS TO FURNACES

INBA CAST HOUSE SGP• GRANULATE SLAG PRODUCED IN BF – 1 & 4• TRANSPORT GRANULATED SLAG TO

BUNKER / STORAGE YARD

DE-SULPHERISATION PLANT• DESULPHERISE HIGH “S” HOT METAL (MAX 4

LADLES AT A TIME

WORKSHOP• MACHANICAL REPAIR JOBS

• FITTING / ASSEMBLY OF PLANT EQUIPMENT

• FABRICATION OF SPARE PARTS

FUNCTIONS OF DIFFERENT UNITS

PUG MILL• PREPARE MUDGUN CLAY

• PREPARE CAST HOUSE TROUGH / RUNNER MASS

• PREPARE PCM TROUGH & RUNNER CLAY

FUTURE TECHNOLOGY IN BLAST FURNACE WILL AIM AT

PRODUCTIVITY LEVEL OF 2.0 T/M3/DAY FOR LARGE FURNACES

TOTAL FUEL REQUIREMENT LESS THAN 500 KG/THM

COAL DUST > 100 KG/THM

OXYGEN > 3.0 %

SILICON IN HOT METAL 0.3 %

CAMPAIGN LIFE TO 15 YEARS

INCREASED AVAILABILITY TO 100 % BETWEEN SCHEDULE STOPS

ON-LINE AUTOMATIC CONTROL OF BLAST FURNACE

IMPROVED ENVIRONMENTAL CONTROL

ACHIEVE 4.1 MT PRODUCTION / YEAR FROM 2010 – 2011

BF # 1 : 1500 T

BF # 2 : 1500 T

BF # 3 : 1500 T

BF # 4 : 2500 T

BF # 5 : 4500 T

DAILY PRODUCTION : 11,500 T

PLAN FOR FUTURE

UP COMING NEW PROJECTS IN BF

COAL TAR INJECTION PLANT IN BF # 1

COAL DUST INJECTION IN BF # 1 & 4

CONSTRUCTION OF BF # 5

SALIENT FEATURESSALIENT FEATURES1.1. NEW FURNACE SHELL WITH A NEW PROFILE, FREE NEW FURNACE SHELL WITH A NEW PROFILE, FREE

STANDING STANDING

2.2. REPLACEMENT OF UPTAKES, DOWN COMERS, REPLACEMENT OF UPTAKES, DOWN COMERS, BUSTLE PIPE & DUST CUTOFF VALVEBUSTLE PIPE & DUST CUTOFF VALVE

3.3. STAVE COOLERS IN HEARTH TO STACK + 28 MTR STAVE COOLERS IN HEARTH TO STACK + 28 MTR LEVELLEVEL

4.4. INTRODUCTION OF BREAST COOLERSINTRODUCTION OF BREAST COOLERS

5.5. NEW HOT WATER PUMP HOUSE FOR OVERHEAD NEW HOT WATER PUMP HOUSE FOR OVERHEAD RETURN RETURN WATER LINESWATER LINES

6.6. INCREASE IN BOG DEPTH OF FURNACEINCREASE IN BOG DEPTH OF FURNACE

7.7. COMMISSIONING OF NEW GAS CLEANING PLANT WITH COMMISSIONING OF NEW GAS CLEANING PLANT WITH VENTURY SCRUBBER.VENTURY SCRUBBER.

8.8. NEW SKIP BRIDGE & MAIN SKIPSNEW SKIP BRIDGE & MAIN SKIPS

9.9. HIGHER CAPACITY WINCH FOR MAIN SKIPS & NEW HIGHER CAPACITY WINCH FOR MAIN SKIPS & NEW WINCH WINCH HOUSEHOUSE

10.10. HIGHER CAPACITY COKE & SINTER SCREENSHIGHER CAPACITY COKE & SINTER SCREENS

11.11. REVIVAL OF DEDUSTING SYSTEMREVIVAL OF DEDUSTING SYSTEM

ENVIRONMENTAL PROTECTION MEASURES

FUME EXTRACTION AND COLLECTION FROM FURNACE

TAP HOLE

COVERED RUNNERS WITH EXTRACTION AND

COLLECTION OF FUME

EXTRACTION AND COLLECTION AT THE TORPEDO

LADLE DURING FILLING

PROGRESSIVE MOVES AWAY FROM OPEN AIR

COOLING OF SLAG IN PITS, TO ITS GRANULATION AND

PELLETISATION

MONITORING OF THE FURNACE TOP BY CAMERAS FOR

GAS AND DUST EMISSION FOR CHARGING SYSTEM

AND BLEEDERS.

UNIT COST OF HOT METAL (2005 – 06)

  APP APR MAY JUN JUL AUG SEP OCT NOV DEC TOT

FIXED COST

2267 2358 2859 2979 3024 2626 2719 2067 2205 2181 2546

VARIABLE COST

7834 6536 6568 6837 6892 7297 6926 7315 7198 7412 6622

IWC 96 111 112 120 124 117 115 92 94 87 90

WORKS COST

10197 9005 9539 9936 10040 10040 9760 9474 9497 9680 9258

DEPR. COST

537 575 619 654 662 685 646 512 527 515 572

INTEREST COST

156 166 179 189 191 198 187 148 152 150 174

TOTAL COST

10890 9746 10337 10779 10893 10923 10593 10134 10176 10345 10004

CONCLUSION BLAST FURNACE TECHNOLOGY WILL CONTINUE TO SUPPLY

BULK OF HOT METAL FOR STEEL PRODUCTION IN YEARS TO COME

DECREASE IN COST OF HOT METAL PRODUCTION IS THE NEED OF THE HOUR AND MORE EFFORTS TO BE PUT IN FUTURE.

THE ECONOMY IN BLAST FURNACE TECHNOLOGY CAN BE ACHIEVED THROUGH DEPENDING LESS AND LESS ON METALLURGICAL COKE WITH SUITABLE INJECTION TECHNOLOGY

INCREASE IN CAMPAIGN LIFE OF BLAST FURNACE IS ANOTHER VERY IMPORTANT AREA OF FOCUS FOR DECREASIONG THE FIXED COST OF HOT METAL

THE AUTOMIC OPERATION OF BLAST FURNACE WITH ONLINE CONTROL USING TECHNIQUES OF EXPERT SYSTEMS WILL LEAD TO STANDARDISATION OF BLAST FURNACE OPERATION AND THUS MORE STABLE OPERATION AND LESS DOWN TIME

THE COST OF HOT METAL PRODUCTION CAN BE SUBSTANTIALLY DECREASED THROUGH USE OF UNDER SIZE MATERIALS IN BLAST FURNACE

SPECIFIC EFFORT ARE REQUIRED TO CREATE ENVIRONMETALLY FRIENDLY ATMOSHPHERE IN CAST HOUSE WITH LESS PHYSICAL LABOUR.