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IRON ORES
ORE
MAGNETITE
62
HEMATITE
(a) RED HEMATITE
60
APPEARANCE
COMPOSITION
BROWN EARTHY
SIDERITE OR SPATHIC
CRYSTALLINE GREY
IRON STONE
42-30
EARTHLY OR STONEY
% OF IRON
Fe 3O4
Fe 2O3
72-
70-
2 Fe 2O33H2O
FeCO 3
FeCO 3
48-35
MAGNETITE:
HEMATITE:(RED)
HEMATITE:(BROWN)
Iron Ores
Location
Makarwal, Swabi, Chitral (PAK),
Land of midnight sun (Sweden),
Pennsylvania(USA), Siberia(Russia)
Magnetite
(Black oxide)
Fe3O4
72.4
Hematite (red,
brown &
black)
Fe2O3
40-65
Limonite &
other
hydroxide
types of ores
2Fe2O3 . H2O
to
Fe2O3 . 3H2O
20-55
Siderite
FeCO3
Low in
Fe
Iron Pyrite
(yellow)
FeS
42
Coke
Pellets, Sinter
Iron Ore
February 2011
Edward Long
BLAST FURNACE
Raw materials
Iron ore magnetite , Hematite ,Siderite
Coke used as fuel
Lime stone /Dolomite/ Silicon used as flux
Flow Diagram
Iron
Ore
Blast
Furnace
Iron
Ore
Mine
Blast
Furnace
Steel Plant
Material
Handling
System
Stack Yard
Flow Diagram
Iron
Ore
Coal
Coke
Oven
Plant
Coke
Blast
Furnace
Metallurgical Coke
Stack
Yard
Steel Plant
Coal
Mine
Transportation by
Material Handling
System
Coke
Blast
Furnace
Material
Handling
System
Stack
Coke
Oven
Plant
Material
Handling
System
Storage Bunker
(Coal Tower)
Stamp
Charging Car
Coal Pushed in
Water
Sprayed
Quenching
Car
Coke
Pushed out
Coke Oven
Battery
Waste Volatile
Substance
Waste
Coke Bridge
Liquid Chemical
Off gas
used as fuel
Flow Diagram
Iron
Ore
Coke
Coke
Oven
Plant
Coal
Flux
Blast
Furnace
Flux
Blast
Furnace
Steel Plant
Flux Section
Stack
Yard
Material
Handling
System
Flux Section
Flux is added in the blast furnace to
remove impurities, by producing slag.
Lime is the most commonly used flux
material. Lime may be used as a flux
in the form of CaO, limestone
(CaCO3), dolomite (magnesium
calcium carbonate) or dolomitic lime
(product obtained from burning or
roasting of dolomite).
Flux Section
Lime is used as a flux in solid,
particulate form and reacts with
impurities in the charge to form a
slag.
It is important that the slag be kept
fluid, not only to increase its ability to
scavenge impurities from molten
metal, but also to permit the slag to
be readily removed from the furnace.
Flux Section
Formation of slag has a adverse effect also.
Lime in reaction with silica or silicates
present in the ore forms dicalcium silicate,
which has 38000C melting point. It form a
coating on lime particles and prevent it
from further reaction.
Auxiliary flux is used for the purpose of
facilitating the reaction between lime and
silica or silicates. Fluorspar is a example of
auxiliary flux.
Flow Diagram
Iron
Ore
Coke
Oven
Plant
Coal
Coke
Blast
Furnace
Flux
Fines
from
different
sources
Sinter
Sinter Plant
Sinter Plant
Blast Furnace
All the raw material is charged into
the blast furnace, from top, through
variable throat armour or any other
means.
The purpose of a blast furnace is to
chemically reduce and physically
convert iron oxides into liquid iron
called "hot metal".
Blast Furnace
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.
The raw materials require 6 to 8 hours to
descend to the bottom of the furnace where
they become the final product of liquid slag
and liquid iron. These liquid products are
drained from the furnace at regular
intervals.
Blast Furnace
The hot air that was blown into the
bottom of the furnace ascends to the
top in 6 to 8 seconds after going
through numerous chemical
reactions. Once a blast furnace is
started it will continuously run for
four to ten years with only short stops
to perform planned maintenance.
Blast Furnace
Blast Furnace