By ishan raina, sem :8th

BHILAI
Presented by AVANI SHARMA

HISTORY OF SAIL BHILAI

Hindustan private steel limited started in1954 In 1957 Bhilai plant was established with assistance from USSR having capacity 1MT. It is fully integrated plant producing both basic and special steel. Ranked amongst top 10 PSU in India in terms of turnover.

PLANT LAY-OUT

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 OF2.4 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 OFBLAST FURNACES. A BF TO PRODUCE 1900 THM/DAY WAS BUILTIN 1950. THE LARGEST BF OF THE WORLD HAVING A USEFUL VOLUME OF 5,580 CU.METRE AND HEARTH DIS OF 15.1 M WAS COMMISSIONEDON 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 COMMISSIONEDIN 1959, 1960 AND 1962 RESPECTIVELY TO PRODUCE 1000 THM/DAY. THE BIGGER FURNACE WAS COMMISSIONED IN 1967 TOPRODUCE 1500 THM /DAY

Introduction
In the BF from top to bottom of the furnace the following process occurs :-Drying, preheating, ejection of hydrate waterIndirect reduction-Direct reduction-Melting . In the top third of the shaft, gas delivers its heat so that the charging materials are preheated and dried. When a temperature of 400C to 500C is reached, the water which was fixed with the burden is ejected. Indirect reduction by carbon monoxide occurs below 1000C. At temperatures above 1000C, iron oxide not yet reduced into iron is directly reduced. After melting, the reduction process is completed as hot metal flows through layers of coke.Hot metal produced in the blast furnace is sent to Basic oxygen Furnace for steel making .

What is a Blast Furnace?

Blast Furnace is a counter current heat exchanger.
The purpose of a blast furnace is to reduce and convert iron oxides into liquid iron called "hot metal".

Liquid metal and slag are collected at hearth tappings at regular intervals are done to empty the furnace
Hot metal is sent to sms/pig casting machines. Slag is sent to dump.

Why does Iron have to be extracted in a Blast Furnace???

Temperature of 1800-2000C is possible,so that carbon can reduce iron oxide to iron directly or indirectly. This is more efficient method than electrolysis because it is more cost effective

OBJECTIVE OF BLAST FURNACE

PRODUCT HOT METAL FOR STEEL MELTING SHOP

COMPOSITION

94 % Fe 4.0 % C 0.8 % Si 0.5 % Mn 0.20 % P 0.050 % S 1450C H.M TEMP AT CAST HOUSE

BY-PRODUCTS

LIQUID SLAG / GR. SLAG 32 - 34 % Si02 28- 30 % CaO 10-11 % MgO 0.94 % BASICITY 22-24 % CO CV - 850 K/CAL/M 56 - 58 % N

20 - 22 % Al2O3 1 % MAX FeO BF GAS 2%H 16 -18 % CO2 DUST < 8 Mg/M3

The Method
Three substances are needed to enable to extraction of iron from its ore. The combined mixture is called the charge: Iron ore, haematite - often contains sand with iron oxide, Fe2O3.

Limestone (calcium carbonate).

Coke - mainly carbon The charge is placed a giant chimney called a blast furnace. The blast furnace is around 30 metres high and lined with fireproof bricks. Hot air is blasted through the bottom.

RAW MATERIALS FOR BLAST FURNACES

MATERIALS IRON ORE SINTER LIME STONE Mn ORE QUARTZITE LD SLAG COKE NUT COKE PIG IRON CHIPS SOURCE BARSUAN, KALTA, MEGHATABURU,KIRIBURU, PURCHASED FROM OMC etc. SP I & SP II PURNAPANI, BIRMITRAPUR and PURCHASEDFROM OUTSIDE ROXY, BARAJAMDA, NAGPUR( PURCHASED ) PURCHASED SMS COKE OVENS (COAL FROM DUGDA, BHOJUDIH,KARGALI, RAJRAPPA and Imported coal) COKE OVENS THROUGH SINTER PIG CASTING M/C SHOP

The working of blast furnace

The Process

Several reactions take place before the iron is finally produced...

3fe2o3 + co =co2 +2fe3 o4 Fe3o4 +co =co2 +3feo
begins at 850F

begins at 1100F

. feo
feo

+ co = co2 + fe or + c = co + fe

begins at 1300F

Several reactions take place before the iron is finally produced...

Oxygen in the air reacts with coke to give carbon dioxide: C(s) + O
2(g)

CO2(g)

The limestone breaks down to form carbon dioxide: CaCO3(s) CO2

(g)

+ CaO(s)

Carbon dioxide produced in 1 + 2 react with more coke to produce carbon monoxide:
CO2(g) + C(s) 2CO(g)

 The carbon monoxide reduces the iron in the ore to give molten iron:

3CO(g) + Fe2O3(s) 2Fe(l) + 3CO2(g)

The limestone from 2, reacts with the sand to form slag (calcium silicate): CaO(s) + SiO(s) CaSiO3(l)

Both the slag and iron are drained from the bottom of the furnace. The slag is mainly used to build roads. The iron whilst molten is poured into moulds and left to solidify - this is called cast iron and is used to make railings and storage tanks. The rest of the iron is used to make steel.

The blast furnace plant

High Top Pressure

Reduction of Coke rate More wind acceptance Better Si control Fast drainage

Tools to improve productivity

High top pressure High enrichment (Oxygen and auxiliary fuel) Reduced coke rate High percentage of prepared burden Better distribution Improved drainage practice Better Raw material quality Better sensing equipments

Conclusion:
The b/f is the 1st step in producing steel from iron oxides. The 1st B/f appeared in the 14th century and produce one tons per day.now Modern,giant furnaces produce 13,000 tons per day. The steel industry will move toward higher value added products in the future. In order to support the value added steel products, iron sources have to be secured with stable operation of furnaces.