Integration of the Blast Furnace Route and the FINEX®-Process for Low CO2 Hot Metal Production

A six day industrial trial using hydrochar as part of the carbon source for hot metal production was performed in a production blast furnace (BF). The hydrochar came from two types of feedstocks, namely an organic mixed biosludge generated from pulp and paper production and an organic green waste residue. These sludges and residues were upgraded to hydrochar in the form of pellets by using a hydrothermal carbonization (HTC) technology. Then, the hydrochar pellets were pressed into briquettes together with commonly used briquetting material (in-plant fines such as fines from pellets and scraps, dust, etc. generated from the steel plant) and the briquettes were top charged into the blast furnace. In total, 418 tons of hydrochar briquettes were produced. The aim of the trials was to investigate the stability and productivity of the blast furnace during charging of these experimental briquettes. The results show that briquettes containing hydrochar from pulp and paper industries waste and green waste can partially be used for charging in blast furnaces together with conventional briquettes. Most of the technological parameters of the BF process, such as the production rate of hot metal (<1.5% difference between reference days and trial days), amount of dust, fuel rate and amount of injected coal, amount of slag, as well as contents of FeO in slag and %C, %S and %P in the hot metal in the experimental trials were very similar compared to those in the reference periods (two days before and two days after the trials) without using these experimental charge materials. Thus, it was proven that hydrochar derived from various types of organic residues could be used for metallurgical applications. While in this trial campaign only small amounts of hydrochar were used, nevertheless, these positive results support our efforts to perform more in-depth investigations in this direction in the future.

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Technological advancements in evaluating the performance of the pulverized coal injection through tuyeres in blast furnace

Metallurgical Research & Technology ◽

10.1051/metal/2020068 ◽

2020 ◽

Vol 117 (6) ◽

pp. 611

Author(s):

Ashish Agrawal ◽

Rohit Kumar Tiwari ◽

Sanjiv Kumar ◽

Rajeswar Chatterjee ◽

Basant Kumar Singh ◽

...

Keyword(s):

Blast Furnace ◽

Pulverized Coal ◽

Injection System ◽

Metallurgical Coke ◽

Hot Metal ◽

Metal Production ◽

Replacement Ratio ◽

Pulverized Coal Injection ◽

Factors Influencing ◽

Coal Injection

The pulverized coal injection (PCI) is pursued to reduce the hot metal production cost by replacing the expensive metallurgical coke with the non-coking coal. Increasing the PCI rate causes various difficulties in the blast furnace (BF) operation. In the present work, an attempt is made to review the various aspects of PC injection in BF such as the challenges with increasing the PCI rate and modifications in the injection system to circumvent the concerns related to higher PCI rate. Various methods for detecting the tuyere blockage and failure caused due to the high PCI rate are elaborated. The factors influencing the combustion of coal in front of tuyeres have been discussed and their impact in the replacement ratio has been discussed. Further, recommendations are made to improve the coal combustibility in front of tuyeres.

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Ecological hot metal production using the coke plant and blast furnace route

Revue de Métallurgie ◽

10.1051/metal:2005140 ◽

2005 ◽

Vol 102 (3) ◽

pp. 171-182 ◽

Cited By ~ 8

Author(s):

P. Schmöle ◽

H.-B. Lüngen

Keyword(s):

Blast Furnace ◽

Coke Plant ◽

Hot Metal ◽

Metal Production

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Wear-Model-Based Analysis of the State of Blast Furnace Hearth

Metallurgical and Materials Transactions B ◽

10.1007/s11663-021-02399-w ◽

2022 ◽

Author(s):

Mikko Helle ◽

Henrik Saxén ◽

Bart de Graaff ◽

Cornelis van der Bent

Keyword(s):

Blast Furnace ◽

Heat Conduction Problem ◽

Poor Performance ◽

Inverse Heat Conduction Problem ◽

Force Balance ◽

Inverse Heat Conduction ◽

Hot Metal ◽

Wear Model ◽

Metal Production ◽

Erratic Behavior

AbstractThe condition and state of the hearth of the blast furnace is of considerable importance since the life length of the refractories governs the campaign length of the furnace, but it is also of significance as it affects the drainage of iron and slag and the hot metal temperature and composition. The paper analyses the hearth of a blast furnace using a model of the lining wear based on the solution of an inverse heat conduction problem, studying the changes in the lining state throughout the campaign. Different operation states are detected, characterized by smooth and efficient hot metal production and by erratic behavior with large disturbances in the hearth state. During the periods of poor performance, the hearth exhibits a cycling state with stages of excessive skull growth on the unworn refractory, followed by periods of dissolution of the skull and lining erosion. An explanation of the transitions is sought by a stating and solving a force balance for the deadman with the aim to clarify whether it is floating or sitting. A connection between the thermal cycles in the hearth and the hot metal sulfur content is finally demonstrated.

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Analysis of the Influence of Biomass Addition in Coal Mixture for Metallurgical Coke Production

Global Journal of Researches in Engineering ◽

10.34257/gjreevol21is2pg1 ◽

2021 ◽

pp. 1-9

Author(s):

Alex M. A. Campos ◽

Paulo S. Assis

Keyword(s):

Blast Furnace ◽

Co2 Emissions ◽

Environmental Issues ◽

Coke Production ◽

Partial Replacement ◽

Metallurgical Coke ◽

Hot Metal ◽

Short Term ◽

Metal Production ◽

Coal Mixture

Metallurgical coke is a common material used for hot metal production in blast furnaces. In addition to the fuel function, it has a physical assignment, supporting the load inside the reactor, and chemical, supplying carbon to hot metal. However, due to growing discourse on environmental issues, the production of hot metal via coke blast furnace has been in evidence. This process is responsible for about 70% of CO2 emissions in steelmaking. On the other hand, biomasses are materials that are available in different ways in nature and considered neutral in CO2 emissions since they absorb this gas and release oxygen in the photosynthesis process. Thus, a viable alternative in the short term is the partial replacement of the coal used in coke production with biomass, which would generate environmental gains, and guarantee the sustainable production. Therefore, this work aims to show several published researches using biomass in coke production. The effects that biomass has on the properties of coke will be emphasized, and at the end, an environmental analysis will be shown with the possible use of biomass. It will be possible to see that it is possible to substitute between 2 and 10% of the coal for biomass, producing coke with the characteristics required in the blast furnace.

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Diagnostics, Optimization and Mathematical Models of Coke-Sinter-Hot Metal Production Process

AISTech2019 Proceedings of the Iron and Steel Technology Conference ◽

10.33313/377/050 ◽

2019 ◽

Author(s):

O. Lebid ◽

Y. Vyshinskya ◽

N. Gordon ◽

V. Chaika ◽

G. Izumskiy ◽

...

Keyword(s):

Mathematical Models ◽

Production Process ◽

Hot Metal ◽

Metal Production

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Effect of BaO on silica activity in blast furnace slag and silicon distribution between slag and hot metal

Ironmaking & Steelmaking ◽

10.1179/174328106x80055 ◽

2006 ◽

Vol 33 (2) ◽

pp. 120-128 ◽

Cited By ~ 2

Author(s):

M. Meraikib

Keyword(s):

Blast Furnace ◽

Blast Furnace Slag ◽

Hot Metal ◽

Silica Activity ◽

Furnace Slag

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Adjustment of a technology of cast iron smelting in the blast furnace of jsc "ural steel" w ith a volume of 1232 см3 with charge h a v in g 95% share of Mikhailovskii GOK pellets

Ferrous Metallurgy Bulletin of Scientific Technical and Economic Information ◽

10.32339/0135-5910-2021-7-768-775 ◽

2021 ◽

Vol 77 (7) ◽

pp. 768-775

Author(s):

I. F. Iskakov ◽

G. A. Kunitsyn ◽

D. V. Lazarev ◽

А. А. Red`kin ◽

S. A. Trubitsyn ◽

...

Keyword(s):

Blast Furnace ◽

Iron Ore ◽

Raw Materials ◽

Raw Material ◽

Material Base ◽

Hot Metal ◽

Charging System ◽

Iron Smelting ◽

Gas Consumption ◽

A Charge

To use effectively internal raw material base, JSC “Ural Steel” accomplished I category major overhaul of the blast furnace No. 2. The main purpose of the overhaul was to design a rational profile which could ensure an ability to operate with a charge containing 95 % of Mikhailovskii GOK (mining and concentrating plant) pellets having basicity of 0.5 by CaO/SiO2. The blast furnace No. 2 having useful volume of 1232 m3, was constructed by design of Danieli Corus, the Netherlands, and was blown in on December 30, 2020. In the process of guarantee tests, step-by-step increase of Mikhailovskii GOK pellets (Fetotal = 60.5 %, CaO/SiO2 = 0.5) content in the charge iron ore part was being accomplished from 55 to 95.1%. Charging of the blend containing pellets in the amount of 55% of iron ore part, was done by charging system 4OOCC + 1COOCC (Ore - Coke) with filling level 1.5 m. Under conditions of pellets part increase in the blend, the charging system was changed to decrease their content at the periphery, to increase it in the ore ridge zone and make it intermediate between periphery and the ore ridge. At the pellets share in the iron ore raw materials 0.75 the charging system was used as the following: 3OOCC + 1COOC + 1COOCC, while at the content 95.1% the following charging system was used: 2COOC + 2COOC + 1COOCC. It was noted that in the period of guarantee tests the furnace running was smooth. The average silicon content in the hot metal was 0.70% at the standard deviation 0.666. Sulfur content in the hot metal did not exceed 0.024%, the blowing and natural gas consumption figures were 2100 m3/min and 11000 m3/min correspondently, oxygen content in the blowing 26.5%, hot blowing and top smoke pressure figures were 226.5 and 109.8 KPa correspondently. The productivity of the furnace was reached as high as 2358 t/day at the specific coke rate 433 kg/t of hot metal. After guarantee tests completion, the pellets content in the iron ore part was decreased gradually from 95 down to 50%. The decreasing was made by 5% in every 6 hours of operation. Application of the mastered technology of the blast furnace No. 2 with the increased share of pellets will enable to stably supply the blast furnaces No. 1, 3 and 4 by iron ore raw materials in the proportion of 30-35% of pellets and 65-70% of sinter.

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