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A big blast furnace is an industrial machine for producing pig iron by smelting iron ore together with coke and limestone. It is the main part of the iron-making component in integrated steel mills. There are mainly two types of big blast furnaces.
Conventional blast furnace
A conventional big blast furnace has a vertical shaft and a large, cylindrical body, which are both made of steel and lined with heat-resistant refractory materials. The furnace is divided into several parts, each with a specific function in the smelting process. The wide top part of the furnace is called the ''hopper'' or ''bell'', and it serves as the entry point for the raw materials, including iron ore, coke, limestone, and other additives. Ingredients are loaded into the furnace in alternating layers. A narrow area called the ''throat'' follows the hopper. Due to the cooling system, which is located outside the furnace, the temperature in the throat is lower than in the other sections. This causes the materials to solidify and form clogs due to high pressure. The enormous pressure and high temperature in the lower parts of the furnace cause chemical reactions to occur, transforming the raw materials into molten iron and slag. The lower part of the big blast furnace is called the ''tuyere zone'', in which pure oxygen is injected through tuyeres or nozzles. The temperature here can reach 2000 degrees Celsius, which causes the coke to burn rapidly. The tuyere zone is the hottest part of the furnace. The molten iron flows into a refractor-lined container called a ''cinder pot'' or ''iron pot'', while the slag has lower density and floats on top of the molten iron and solidifies as slag cinder.'}
Coreless induction blast furnace
An improved technology of the big blast furnace is the coreless induction blast furnace. This kind of furnace produces molten iron and eliminates the core of blast furnaces. The design includes a double wall of steel pipes. Strong electric coils heat the inner pipe. The outer cools the molten iron by circulating water through it. The coreless induction blast furnace has many benefits. One of these is that it has large-sized components. Therefore, operators can maintain and clean them easily. The quality of the molten iron is very good. In addition, the energy consumption of the induction blast furnace is lower. The modification of the inner coil design and the cooling of the outer tube control energy use. The installation is simple and takes up less space than conventional blast furnaces. The whole process of producing molten iron is quicker, easier, and more efficient. Therefore, coreless induction blast furnaces have become a popular choice in the industry.
Specifications of the big blast furnace are as follows:
Like other industrial machines, blast furnaces also need maintenance and care to work well for a long time and avoid breaking down. Regular and preventive maintenance can keep them efficient, cost-effective, safe, and environmentally friendly.
Big blast furnaces are industrial giants that underpin the global economy. They are primarily utilized by iron and steel mills. Around 80% of the raw iron produced goes to make steel, which is essential to the construction industry, machinery manufacturing, and the automotive sector. Without blast furnaces, there would be no steel to make bridges, buildings, and vehicles. The wide usage of steel in different products is a testament to the vital role blast furnaces play in iron and steel production.
Ecclesiastical architecture and spires, structural frames, and scaffolding, construction material, rail tracks and rolling stock, pipelines, bridges, and offshore oil rigs are typical products made from steel generated in blast furnaces. Oil pipelines, including the Keystone pipeline that stretches from Canada down to Illinois, and offshore oil rigs, often use steel made from blast furnace-produced iron. Special grades of steel can withstand the pressure changes and salt water at offshore oil fields.
As mentioned above, the construction industry, pipelines, and automotive sectors rely heavily on steel. More than 1,600 billion metric tons of steel are produced worldwide.
Despite their size and complexity, big blast furnaces are efficient and productive, making them essential to the iron and steel industries.
When selecting a big blast furnace for business needs, there are several important factors to consider.
Capacity and Production Requirements
When it comes to choosing a big blast furnace, the first thing to consider is its capacity and production requirement. Business buyers should be clear about the annual or monthly output of iron ore that they need. In addition, they should match the productivity of the furnace with their production plan. They could also take into account factors such as market demand fluctuations or potential expansion of operations.
Furnace Design and Technology
Among the big blast furnace options available in the market, business buyers need to choose the one that fits their specific needs. They could first evaluate the design of the furnace, which includes horizontal and vertical models. Then they may explore all available technologies, such as the shaft furnace, which employs counter-current gas and solid material flow to efficiently reduce iron ore. The blast furnace converter is also studied by business buyers, which makes use of oxygen blowing to produce high-quality steel from molten iron. In addition, the focus may also be put on other advanced technologies, such as hot metal desulfurization and oxygen enrichment systems.
Operating Efficiency and Environmental Compliance
Another critical aspect that needs to be taken into serious consideration when choosing a big blast furnace is its operating efficiency. Buyers may consider the thermal efficiency of the furnace, which directly influences energy consumption. They should also evaluate the gas utilization efficiency of the equipment. This is important, as the proper use of blast furnace gas can reduce the overall operating cost. More importantly, business buyers need to ensure that the big blast furnace they choose complies with local environmental regulations. The emission control systems should be properly functioning, and the waste treatment facilities should be in good shape.
Q1: Which raw materials are used in the blast furnace process?
A1: The primary raw materials are iron ore, coke, and limestone. However, some blast furnaces use alternative materials like Direct Reduced Iron (DRI), Pellets, and Natural Minerals to optimize efficiency and quality.
Q2: What type of steel does a big blast furnace make?
A2: The blast furnace primarily produces pig iron, which is then converted into various types of steel. The pig iron can contain high levels of carbon and may include other elements like silicon, manganese, phosphorus, and sulfur. Steel manufacturers class steel according to carbon levels. Blast furnaces will produce pig iron with carbon levels that are perfect for low, medium, and high carbon steel.
Q3: How does the blast furnace differ from the cupola furnace?
A3: The role of a big blast furnace in the production of iron is parallel to that of the cupola furnace. However, while the blast furnace relies on chemical processes for iron production, the cupola primarily facilitates melting through the application of heat generated by layers of coke and charged materials.
Q4: What is the life span of a big blast furnace?
A4: Modern blast furnaces are designed for long campaign lives and typically operate for 10 to 15 years or longer without major shutdowns for repairs.
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