Blast Furnace Reactions with Diagram (16 Marks)
1. Introduction: CaO + SiO₂ → CaSiO₃ (slag formation)
A blast furnace is used to convert iron ore into hot metal (pig iron) using
coke as a reducing agent and limestone as a flux
2. Zones in Blast Furnace:
Throat: Charging point Zones,
Stack: Preheating and drying Raw material input (ore, coke, flux),
Belly: Transition zone Reactions,
Bosh: High-temperature reduction Hot blast tuyeres,
Hearth: Collection of hot metal and slag Gas flow upward,
Molten metal and slag tap)
---
3. Major Reactions: ---
a. Drying and Preheating (Top Zone): 5. Final Products:
H₂O (moisture in ore) → H₂ + O₂ (evaporation) Hot Metal (Pig Iron): ~4% C, Si, Mn, S, P
Slag: Silicates, alumina, lime
b. Indirect Reduction (400–900°C):
Top Gas: CO, CO₂, N₂ (used for stoves)
3Fe₂O₃ + CO → 2Fe₃O₄ + CO₂
Fe₃O₄ + CO → 3FeO + CO₂
---
FeO + CO → Fe + CO₂
6. Conclusion:
c. Direct Reduction (1000–1600°C): The blast furnace efficiently reduces iron oxides to molten iron through a
series of chemical reactions distributed across temperature zones, aided
FeO + C → Fe + CO by well-prepared raw materials and hot air injection.
COREX Process with Diagram (16 Marks)
d. Combustion at Tuyeres: 1. Introduction:
The COREX process is a smelting reduction technology developed as an
C + O₂ → CO₂ alternative to the blast furnace, capable of using non-coking coal and iron
ore directly, eliminating the need for coke oven.
CO₂ + C → 2CO (Boudouard Reaction)
2. Process Overview:
e. Fluxing Reaction: COREX consists of two main reactors:
CaCO₃ → CaO + CO₂
Reduction Shaft (top unit): Iron ore is pre-reduced to DRI using reducing 6. Limitations:
gases.
High capital investment
Melter-Gasifier (bottom unit): Non-coking coal is gasified to produce CO
and H₂, which act as reducing gases and also melt the pre-reduced iron. Sensitive to raw material quality
3. Reactions:
Requires trained personnel and advanced automation
In the Melter-Gasifier:
C + O₂ → CO₂
---
CO₂ + C → 2CO
7. Applications:
C + H₂O → CO + H₂
Used in steel plants like JSW (India)
Fe + heat → molten hot metal
Suitable for regions lacking coking coal
In the Reduction Shaft:
Fe₂O₃ → Fe₃O₄ → FeO → Fe (using CO and H₂) ---
4. Diagram:
8. Conclusion:
(Include a labeled diagram showing:
COREX is an eco-friendly and efficient ironmaking process ideal for
Iron ore and coal input integrated steel plants aiming for energy efficiency and environmental
compliance.
Reduction shaft
Melter-gasifier
The SL/RN process (Stenkol–Lurgi/Republic Steel–National Lead) is a
Flow of reducing gas coal-based rotary kiln process used for producing sponge iron (DRI).
Product hot metal and slag tap
---
Export gas line)
Key Features:
5. Advantages:
Rotary kiln is used for reduction.
No need for coking coal or sinter plant
Uses non-coking coal as both reductant and heat source.
Lower CO₂ emissions compared to blast furnace
Iron ore is reduced in solid state.
Export gas can be used for power generation or DRI production
Flexibility in raw materials
---
Raw Materials:
---
Lump iron ore or pellets
---
Non-coking coal
Key Features:
Dolomite or limestone (for desulfurization)
Reducing gas: CO + H₂ derived from natural gas reforming.
Shaft furnace used for reduction.
---
High metallization efficiency (~92–95%).
Process Steps:
1. Charging:
---
Iron ore, coal, and flux are fed into the rotary kiln.
Raw Materials:
Iron ore pellets/lumps
2. Pre-heating Zone:
Natural gas (CH₄)
Charge is heated by burning coal at one end of the kiln.
Steam (H₂O)
3. Reduction Zone:
---
Fe₂O₃ + CO → Fe + CO₂
Process Steps:
Fe₂O₃ + C → Fe + CO
1. Gas Reforming:
Natural gas + steam → CO + H₂
4. Discharge:
CH₄ + H₂O → CO + 3H₂
Sponge iron is cooled and separated from char and ash.
2. Reduction:
Iron ore is reduced in solid state in a shaft furnace.
---
Reactions:
Advantages:
Fe₂O₃ + 3H₂ → 2Fe + 3H₂O
Uses cheap coal
Fe₂O₃ + 3CO → 2Fe + 3CO₂
Simple and flexible operation
The Midrex process is a gas-based direct reduction (DR) method used to
produce sponge iron (DRI) using natural gas (mainly CH₄).
3. Product Handling:
Hot DRI is either cooled or briquetted.
Off-gases are recycled after cleaning. ---
Advantages of HYL III:
High metallization
--- High energy efficiency
Advantages: Better gas utilization
High productivity The Corex process is a smelting reduction method that produces hot
metal using non-coking coal instead of coke, offering an alternative to the
Lower carbon emissions blast furnace route.
High energy efficiency
---
Key Features:
The HYL process is a gas-based direct reduction (DRI) technology, Two main reactors: Reduction Shaft and Melter-Gasifier
originally developed in Mexico. Over time, it evolved through three stages
(I, II, III), with improvements in efficiency and productivity. Uses non-coking coal directly
High degree of metallization before smelting
---
Common Features of All Versions:
---
Use of reformed natural gas (CO + H₂).
Steps in Corex Process:
Iron ore is reduced in a shaft furnace.
1. Reduction Shaft:
No need for external coal or coke.
Iron ore is pre-reduced using recycled reducing gas (CO + H₂)
~85% metallized DRI is produced.
---
Differences Between HYL I, II, and III:
2. Melter-Gasifier:
--- Coal is gasified with oxygen to generate reducing gas.
Reduction Reactions: Hot metal and slag are produced.
Fe₂O₃ + 3H₂ → 2Fe + 3H₂O C + O₂ → CO₂, CO₂ + C → 2CO (gasification)
Fe₂O₃ + 3CO → 2Fe + 3CO₂ DRI melts and collects as hot metal.
3. Flux (Limestone / Dolomite):
3. Gas Recycling:
Function: Combines with gangue (SiO₂, Al₂O₃) to form slag
Off-gas from melter is cleaned and reused for reduction.
Reactions:
Excess gas can be used for power generation.
CaCO₃ → CaO + CO₂
CaO + SiO₂ → CaSiO₃ (slag)
---
Advantages: ---
Eliminates coke ovens and sinter plants 4. Hot Air (Blast):
Lower CO₂ emissions Preheated to 1000–1300°C and blown through tuyeres
Co-generation of valuable export gas Promotes combustion and maintains temperature
A blast furnace uses a mix of iron-bearing materials, fuel, and fluxes to ---
produce hot metal. Each material plays a specific role in the iron-making
process. 5. Auxiliary Fuels (optional):
Pulverized coal, natural gas, oil
---
Used to reduce coke consumption
1. Iron Ore (Fe Source):
9. Blast Furnace Refractories
Types: Hematite (Fe₂O₃), Magnetite (Fe₃O₄), Sinter, Pellets, Lump ore
Introduction:
Function: Main source of iron for reduction to molten iron
Refractories are materials that can withstand high temperatures without
melting or degrading. In a blast furnace, they form the inner lining and
protect the steel shell from heat and chemical attacks.
--- Zones of the Blast Furnace & Refractory Types:
2. Coke (Fuel and Reductant): 1. Stack and Shaft Area:
Function: Supplies heat via combustion, acts as a reducing agent, Refractory Type: Fireclay bricks or High Alumina bricks
supports the burden
Function: Withstand abrasion and moderate temperature (up to 1400°C)
Reaction:
C + O₂ → CO₂
2. Belly and Bosh Area:
CO₂ + C → 2CO (reduction gas)
Refractory Type: High Alumina (60–80% Al₂O₃) or SiC bricks
1. Combustion Chamber:
Function: Resist high temperature (1400–1600°C) and chemical corrosion
from slag and hot gases Fuel gas (like coke oven gas, blast furnace gas) is burned with air.
Produces hot flue gases.
3. Tuyere Area:
Refractory Type: Carbon bricks or Graphite blocks 2. Checker Chamber:
Function: Withstand very high temperatures, thermal shock, and chemical Contains checker bricks arranged to absorb and store heat from flue
erosion gases.
4. Hearth (Bottom): Acts as a heat reservoir.
Refractory Type: Carbon-based (carbon, graphite, semi-graphite) bricks
Function: Resist chemical attack by molten iron and slag; excellent 3. Valves and Ducts:
thermal conductivity for heat dissipation
Refractory Lining Structure: Regulate the flow of air, gas, and combustion products between stove
and furnace.
Often multi-layered:
Hot Face Lining (facing the furnace) Working Cycle (2 Phases):
Safety Layer (backup lining) 1. Heating Phase (On-Gas):
Insulation Layer (to reduce heat loss) Stove is heated by burning fuel gas and air.
Hot gases pass through checker bricks and heat them up.
Key Requirements:
High thermal resistance
2. Blowing Phase (On-Blast):
Low thermal conductivity (for insulation layer)
Combustion is stopped.
Good mechanical strength
Cold air is passed through hot checker bricks.
Chemical resistance to slag and gases
Air picks up heat and becomes hot blast.
Low porosity to prevent penetration of molten materials
Sent to blast furnace tuyeres.
10. Blast Furnace Stove
Purpose:
A Blast Furnace Stove is used to preheat the air (called hot blast) that is > Multiple stoves (usually 3 or 4) operate in rotation: while one is heating,
blown into the blast furnace through tuyeres. Preheated air increases the others are on-blast or cooling.
efficiency and productivity of the furnace.
Components of a Stove: Temperature Achieved:
Hot blast temperature: 900°C to 1300°C
Final Cleaned Gas:
Higher hot blast = better reduction and fuel efficiency
Mostly CO, N₂, and CO₂
11. Blast Furnace Gas Cleaning System Has lower calorific value but can be reused in:
Purpose: Blast furnace stoves
The gas produced in the blast furnace (called BF gas) contains dust, tar, Power plants
and fine particles. It must be cleaned before reuse in stoves or power
generation. Sinter plants
Heating boilers
---
Benefits of Cleaning:
Components of the Cleaning System:
Prevents damage to equipment
1. Dust Catcher:
Increases efficiency and safety
First-stage separator
Reduces environmental pollution
Removes large dust particles by allowing gas to slow down and settle
particles by gravity. 12. Sinter Making (Downdraft Layered Sintering) & Pellet Making
---
2. Cyclone Separator or Gravity Separator:
A. Sinter Making (Downdraft Layered Sintering)
Uses centrifugal force to remove medium-sized dust particles.
Purpose:
To agglomerate iron ore fines with flux and coke breeze into a porous
3. Wet Scrubber / Venturi Scrubber: mass (sinter) suitable for blast furnace use.
Gas is passed through a water spray or high-speed venturi to remove fine
particles and soluble impurities. ---
Produces sludge, which is periodically removed. Process Steps:
1. Raw Material Preparation:
4. Electrostatic Precipitator (Optional): Iron ore fines, coke breeze, flux (limestone/dolomite), and water are
mixed.
Uses electric field to collect fine dust particles from the gas.
5. Gas Cooler (optional in modern plants): 2. Layering:
Cools down the gas before further use. Mixture is spread in layers on a sintering bed (usually a moving grate).
2. Pelletization:
Mixture is rolled in disc or drum pelletizers to form green pellets.
3. Ignition:
Top of the layer is ignited using burners (~1100–1300°C).
3. Drying & Preheating:
Pellets are dried and preheated in a furnace.
4. Downdraft Air Flow:
Air is drawn from below (downdraft), which pulls the flame front downward
through the bed. 4. Induration:
Heated to ~1250°C in an induration furnace to harden pellets.
5. Sinter Formation:
Heat causes partial fusion of particles, bonding them together. 5. Cooling:
Hardened pellets are cooled and sent for use.
6. Cooling & Crushing: Advantages:
Sinter is cooled, crushed, and screened. Oversized is recycled. High strength and uniform size.
Advantages: Better metallurgical properties.
Recycles waste fines. Suitable for gas-based reduction (like Midrex or HYL).
13. Modern Development of Blast Furnace
Improves blast furnace permeability.
A. Bell-less Charging System
Increases productivity and fuel efficiency.
B. Pellet Making Traditional BF charging uses a bell or bell-less hopper to charge burden
materials.
Purpose:
Bell-less charging system uses multiple rotating valves or valves
To agglomerate ultra-fine iron ore (concentrate) into round balls (pellets) controlled electronically to charge the burden smoothly.
for use in BF or DRI processes.
Advantages:
--- Uniform distribution of burden over the cross-section.
Process Steps: Reduces gas channeling and improves furnace permeability.
1. Mixing: Increases productivity and fuel efficiency.
Iron ore concentrate mixed with binders (e.g., bentonite) and moisture. Minimizes wear on furnace lining due to better burden distribution.
Reduces dust emissions.
Role of Slag:
---
Removes impurities from iron (e.g., sulfur, phosphorus).
B. High Top Pressure Operation
Protects molten iron and hearth lining.
Modern BFs operate at higher top gas pressures (up to 3-4 bar),
compared to traditional 1 bar. Controls temperature and viscosity in the furnace.
Benefits: B. Pig Iron Composition
Improved gas utilization and reduction efficiency. Typical Composition:
Higher production rate due to increased gas velocity. Carbon (C): 3.5–4.5%
Increased thermal efficiency. Silicon (Si): 1.0–3.0%
Possibility of recovering more energy from off-gases. Manganese (Mn): 0.2–1.0%
Lower coke consumption. Sulfur (S): 0.05–0.1%
Phosphorus (P): 0.05–0.2%
Challenges:
Iron (Fe): Balance
Requires stronger furnace shell design.
More complex gas cleaning and pressure control systems. Characteristics:
High carbon makes pig iron hard and brittle.
14. Slag & Pig Iron Composition & Gas Composition Used as raw material for steel making
C. Blast Furnace Gas Composition
--- Remarks:
A. Slag Composition Low calorific value gas.
Major Components: Used as fuel gas in stoves, power plants, sinter plants.
Silica (SiO₂): 30–50%
Lime (CaO): 30–45%
Alumina (Al₂O₃): 10–20%
Coke vs Coal (8 Marks)
Magnesia (MgO): 3–8%
1. Definition:
Iron Oxide (FeO): 10–15%
Coal is a naturally occurring sedimentary rock formed from decayed plant
Others: Manganese oxide, phosphorus oxides (small amounts) matter over millions of years.
Coke is a high-carbon, porous material obtained by the destructive 2. Carbon Content:
distillation of coking coal in the absence of air.
Pig Iron contains high carbon (3.5–4.5%), making it brittle and unsuitable
for direct use in most applications.
2. Composition:
Sponge Iron has low carbon content and fewer impurities.
Coal contains 50–98% carbon along with volatile matter (20–35%),
moisture, sulfur, and other impurities.
3. Physical Form:
Coke has a higher carbon content (85–90%) and very low volatile matter
(2–7%). Pig Iron is in molten form during production and solidifies into ingots.
Sponge Iron appears as solid, porous lumps resembling a sponge.
3. Physical Properties:
Coal is soft, brittle, and tends to break easily. 4. Impurities:
Coke is hard, strong, and porous, allowing gases to pass through during Pig Iron has higher levels of silicon, sulfur, phosphorus, and manganese.
metallurgical processes.
Sponge Iron is purer and has controlled impurity levels, which makes it
suitable for electric arc furnaces and steelmaking.
4. Uses:
Coal is primarily used as a fuel for power generation and domestic 5. Applications:
purposes.
Pig Iron is used to manufacture cast iron and steel in foundries.
Coke is used mainly in metallurgy, especially in the blast furnace as a fuel
and reducing agent in iron extraction. Sponge Iron is mainly used as a feedstock in secondary steelmaking
processes.
5. Environmental Aspects: Q1. LD Operation Design – Advantages, Disadvantages, and Diagram
Coal produces more pollutants due to higher volatile matter. Answer:
Coke burns cleaner in industrial use due to reduced impurities. LD Process (Linz-Donawitz Process) is a basic oxygen steelmaking
process where oxygen is blown into molten pig iron to reduce carbon
content and remove impurities.
--- Design:
Pig Iron vs Sponge Iron (8 Marks) Vessel: Pear-shaped oxygen converter lined with basic refractory.
1. Definition: Lance: Water-cooled lance for blowing high-purity oxygen at supersonic
speed.
Pig Iron is the intermediate product of smelting iron ore in a blast furnace,
where iron is melted with coke and limestone.
Steps:
Sponge Iron (Direct Reduced Iron) is produced by direct reduction of iron
ore using gases or coal, without melting the ore. 1. Charging molten pig iron an
