iron making course - blast furnace
TRANSCRIPT
1
CompanhiaVale do Rio Doce
IRONMAKING COURSE
BLAST FURNACE
August 27th 2010, Belo Horizonte, Brazil
Ironmaking Course
Blast Furnace
Metallurgical reactor where the iron oxides and reducing agents are transformed to liquid hot metal (pig iron) and slag is formed from the gangue of iron burden and the ash of coke.
Thermodynamic conditions (gas composition and temperature) inside blast furnace allows impurities incorporation as silicon, carbon, phosphorus and sulphur to pig iron. Another elements go to the slag.
The blast furnace operates in a countercurrent form. The solid burden flows downward as it reacts with the gases flowing upward. These gases are generated by coke combustion with air injected in the bottom of the furnace.
The blast furnace metallic burden is composed by lump, sinter and pellets. Coke is the reducing and fuel agent of the process.
The blast furnace slag can be sold as raw material to cement industry.
Ironmaking Course
Definition of Volume and Productivity
1) Definition of the blast furnace volumes
1) Total Volume: Is the volume of the BF between the bottom layer of the hearth and the stock line (zero level burden)
2) Inner Volume: Is the volume of the BF between the taphole level into the hearth and the stock line (zero level burden)
3) Work volume: is the volume of the BF between the tuyere level and the stock line (zero level burden)
Ironmaking Course
Blast Furnace Facilities and Cross Section
Top of the furnace
Body of the furnace
Gas Cleaner System
Hot Stove – Cowper’s
Auxiliary equipments
Drilling Machine
Blast Furnace Clay Gun
Torpedo Car
Slag Car
Drilling Machine
Blast Furnace Clay Gun
Torpedo Car
Slag Car
Ironmaking Course
Blast Furnace FacilitiesTop of the FurnaceAll BFs have auxiliary equipment such as:
Conveyor belts for transporting raw materials (iron ore and coke) to the top of the furnace.Hoppers for temporarily storing these raw materials before charging.bell-type charging equipment, where raw materials enter the furnace through the gap created by moving down a small inverted bell. This bell closes and a larger bell (big-end-down) opens to allow material to fall into the shaft below.bell-less charging equipment, the raw materials are dropped into the furnace through a rotating chute. This device allows charging the raw materials into the furnace with appropriate distribution in the radial and angular direction.
Ironmaking Course
Blast Furnace Charging Systems
1. Parallel Hopper Bell Less Top®• Normally 2 hoppers• But sometimes 3 material hoppers
2. Central Feed Bell Less Top®• Static receiving hopper• Rotating receiving hopper
3. Compact Bell Less Top®
4. Mini Bell Less Top®
5. Bell and Double Seal Valve Top
Ironmaking Course
Central Feed BLT® withRotating Receiving HopperCentral Feed BLT® with
Rotating Receiving Hopper
Parallel Hopper TopParallel Hopper Top
Series Hopper Top, Central Feed
Series Hopper Top, Central Feed
3-parallel hopper Bell Less Top® (CST)
3-parallel hopper Bell Less Top® (CST)
Mini Bell Less Top®Mini Bell Less Top®
Central Feed BLT® with R H (Sollac)
Central Feed BLT® with R H (Sollac)
Compact type Bell LessTop®
Compact type Bell LessTop®
Ironmaking Course
Advantages of the Bell Less Top® System:
1. Burden Distribution• More flexibility• More Stable Operation
2. Higher Furnace Top Pressure• Improved Furnace Operational Control
3. Reduced Maintenance• Increased Furnace Campaign Life• Increased Furnace Availability
4. Increased Furnace Production
Ironmaking Course
Blast Furnace FacilitiesBody of the Furnace
The blast furnace has a vertical cylindrical structure externally covered with a shell of thick steel plate and internally lined with refractory.The refractory structure is cooled by water-cooled metal components called cooling box or staves, which are assembled between the shell and the refractory wall.The furnace body is composed by (i) the shaft, which tapers outward from the top,(ii) the belly, which is a straight cylinder,(iii) the bosh, which tapers inward toward its bottom and is located immediately under the belly, and(iv) the hearth, at the bottom of the furnace.
Ironmaking Course
Blast Furnace FacilitiesBody of the Furnace
The shaft, belly, and bosh are usually lined with chamotte brick and silicon-carbide brick, and the hearth is lined with carbon brick. Depending on the size of the furnace, the side wall of the hearth is radially fitted with some 20 to 40 of water-cooled copper tuyeres, which are used to inject the hot blast into the furnace from the hot stoves through the hot-blast main and bustle pipes. Tapholes for discharging hot metal and cinder notches for discharging slag are also installed in the hearth section. The largest BFs at present are about 80m in total height, with a furnace body height of about 35m and a maximum internal diameter of about 16m, and have an internal volume of about 5,750 m3
which produce approximately 13,000 tons of hot metal a day.
Ironmaking Course
Blast Furnace FacilitiesAuxiliary equipments
hot stoves for heating the blast,blowers for feeding the blast,equipment for dust removal, and recovering and storing the gas from the furnace top.Blast furnaces in which pulverized coal is injected through the tuyeres are provided with equipment for pulverizing the coal and feeding it under pressure.In the cast house there is a drilling machine for opening the tap hole and the clay gun to close it when the runner finish.Radial probes for gas analyse and temperature. It is assembled above the burden and cover from wall to centre of the furnace.Profilometer for map the burden distribution and measure the descend of charge.
Ironmaking Course
Blast Furnace OperationBlast Furnace Operation
The furnace can be charged with iron ore lumps, pellets, and/or sinter; coke and flux.These are carried to the top of the furnace with skips or belt conveyors, and are distributed, (not tipped) into the furnace.At the same time, preheated air (around 1250°C) is injected through the tuyeres, which are nozzles at the bottom of the furnace.The coke is partially burned by the injected hot air both to produce heat, and to generate carbon monoxide (CO). Since coke is relatively expensive, some furnaces inject coal, tar, natural gas or oil along with the air as supplemental fuels to reduce coke usage.The carbon monoxide travels upward through the shaft, and removes oxygen from the iron ores on their way down, leaving metallic iron. By the time the charge reaches the base of the furnace, the heat generated there melts the iron. The resulting molten “hot metal” is tapped at regular intervals by opening the “tap hole” in the bottom of the furnace so that it can flow out.The fluxes combine with impurities in the coke and ore to form the slag, which floats on the hot metal and is removed through the “granulation system” (another auxiliary equipment).The hot metal from the furnace is collected in specially-constructed railway containers, called “torpedo cars”. The torpedo cars carry the molten iron to the steelmaking furnace.
Ironmaking Course
Blast Furnace OperationBlast Furnace Operation
Blast furnaces are operated continuously without shutdown for years (nowadays around 20 years) or more. If the furnace were allowed to cool, thermal stresses can cause damage to the refractory bricks.
Eventually, the refractory bricks in the furnace will wear away, and at that point the furnace is emptied and shut down so that it can be relined with new bricks. The period between shutdowns is referred to as a “campaign”.
Hot metal taken directly from the blast furnace contains about 94,5% of Fe, 4 -4.5% carbon, as well as a number of other elements. This is referred to as “pig iron” and is the mainl raw material to be converted to steel by refining in the steelmaking process, which reduces the carbon content and removes other impurities like (P, S , Si) to make stronger and more workable and useful product (=steel).
Ironmaking Course
IRON OREFe2O3 MnO2 P2O5 K2O SiO2 CaO Al2O3
SLAG
PIG IRON
BehaviourBehaviour of Different Elements in the BF Processof Different Elements in the BF Process
Fe3O4
FeO
FeO
Fe (99%) Si (10%)
SiO2 CaO Al2O3P2O5
P (95%)
GA
S
K2O
GA
S
Mn (70%)
MnO
GA
S
Mn3O4
MnO
COKEC S ASH
S (5%)C (12%)
GA
S
Ironmaking Course
Blast Furnace SlagMetals are generally extracted from ores which are always associated with impurities, mainly oxides, called gangue.
During the extraction of the metal, the gangue is removed, by addition of flux, and form the slag, an homogeneous melt (solution) of oxides, which is insoluble in the metal.
Blast furnace slag is formed from the acidic gangue of the metallic burden, ashes of the coke and auxiliary injected fuels and basics fluxes as limestone and/or dolomite.
Four major components amount to about 96% of the slag (CaO, SiO2, Al2O3 and MgO)
During the process, firstly a primary slag is formed during melt process and before the solution of the coke ash components into the slag.
After the the primary slag progress to a final slag.
96%96%Total
8-20%10%Al2O3
28-38%36%SiO2
6-12%10%MgO
34-42%40%CaO
RangeTypical
(CaO+MgO)/ (SiO2+Al2O3)B4
(CaO+MgO)/SiO2B3
CaO/SiO2B2
Typical Slag Composition
Definitions of Basicity
Ironmaking Course
Blast Furnace Cross Section: Internal view
COUNTERCURRENT PROCESS
GOOD PERMEABILITY IN
THE BED IS ESSENTIAL!!!
Raw Materials
Exhaustion Gas
Tuyere
Tap Hole
Slag
Pig Iron
CokeOre
Granular Zone
CoesiveZone
DrippingZone
Hearth
Ironmaking Course
Solid Move Down and Gas Come Up Inside the Blast Furnace GRANULAR ZONE
ORE LAYER
COKE LAYER
TEMP. BEGIN MELTING
COESIVE LAYER
TEMP. MELTING
COKE WINDOW
FLUXODE GÁS SOFTENING
& MELTING ZONE
COKE COMBUSTION
SLAGMETAL
pre-heated air (1100°C) is injected into tuyeres.
combustion of coke (C) with pre-heated air (O2) produces energy to burden heating and reduction.
hot gases cross the bed of coke and ore, heating them and accomplish the chemical reactions of the process.
GASburden top charged is heated
SOLID
iron oxide reduction reactions are started.
the reduced iron oxides are melted.
pig iron and slag are settled in the hearth and separated by density, from where they are tapping.
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CompanhiaVale do Rio Doce
IRONMAKING COURSE
REDUCTANT/FUEL TO BLAST FURNACE
August 27th 2010, Belo Horizonte, Brazil
Ironmaking Course
Coke Production
Coke is the solid residue from destillation (progressive heating in an air free environment) of a coal blending, in a temperature range of 1000 ~ 1200C, in a series of thin furnaces called coke oven.
The distillation process generates many products like gases, condensables, benzol, tar, etc., sold by the steel industry. The internal consumption of coke oven gas is very important for the global energy balance of the works.
The process could last 20 hours. The incandescent product is discharged by pushing and wet or dry quenched
The environmental aspects related to coke oven emissions are a critical problem. A lot of units have been shut down in the world. INCANDESCENT
COKE INSIDE THE OVEN
Ironmaking Course
Coke Oven View
DrawingDrawing MachineMachine
Charging Car
CokeCoke GuideGuide
Coke Ovem View
Ironmaking Course
Coke Oven Operations
Empty Furnace
Coking
Discharge
Charge Leveling
Charged Furnace
Ironmaking Course
Coke Quality Evaluation
Size Distribution
Tumble Index
CO2 Reactivity
Chemical Analysis
Ironmaking Course
Preparation of the blast furnaceburden
Components of the charge to a blast furnace:
An important aspect of the blast furnace process is the preparation of the charge materials, in order to ensure the gas flow through the burden column. Iron ores (hematite Fe2O3 or magnetite Fe3O4) are charged into blast furnace in the form of lump ores, sinter and pellets. The main components of the charge to a blast furnace are:
• Lump Ore • Pellet • Sinter • Fluxes • Coke
Lump ores:The lump ore are naturally mined ores that are crushed and screened to a certain grain size before their use. However, as a result of preparation and enrichment processes in the iron ore mines to increase the Fe content, very fine-grained ores are generated which have to undergo agglomeration before used in blast furnace. This is done by means of pelletizing and sintering.
Ironmaking Course
Components of the charge to a blast furnace:
Pellets:Pelletizing involves the forming of ore fines (pellet feed) and concentrates with grain sizes of well under 1 mm into pellets measuring around 10 to 15 mm in diameter. To do this, the ore mix is moistened and a binding agent added. The "green" pellets are then formed in rotating drums or on rotary discs . These green pellets are dried and indurated at temperatures of more than 1000 °C. This can take place in shaft or rotary furnaces or on a travelling grate. Pellet plants are generally located at the iron ore producers.
Sinter:The sintering is performed at sintering plants, measuring more than 4 m in width and over 100 m in length. Sintering involves charging a mix of ore fines together with coke breeze, fluxes, in-plant returns and return fines, and igniting the coke breeze contents in the surface by means of gas flames in an ignition furnace. A stream of gas or air is drawn from top to bottom through the mix. A flame front passes through the thick layer over the strand length and agglomerates the mix into coarse lumps of ore. Normally, sintering plants are located on the works sites of the steel producers.
Preparation of the blast furnaceburden
Ironmaking Course
Fluxes:When metal is smelted, the metal is separated from its impurities by melting, with the impurities forming a molten slag on top of the metal. Many of the impurities associated with iron ore are difficult to melt, and so they will not form a proper slag easily, which retards the smelting process.
To make these impurities easier to melt, fluxes are added Limestone (CaCO3) or dolomite ((Ca,Mg)CO3) are two typical fluxes used in blast furnaces.
When a large amount of sulfur needs to be removed from the furnace charge, limestone is the preferred flux. Limestone is also a better flux to use if slag from the blast furnace is to be used as a raw material for cement manufacture.
An important criterion for flux selection is availability and cost, and dolomite is often more readily available and less expensive than limestone.by gas chemical reactions
Preparation of the blast furnaceburden
Ironmaking Course
All the iron ore charged contain oxygen, which has to be removed through reduction in the blast furnace process. To do this, carbon is used.The most important source of carbon is metallurgical coke, which nowadays is produced in modern, environmentally friendly coking plants. The coke ovens, are heated by the coking coal in coking chambers, closed off from the outside air, in the course of which the volatile constituents such as coke oven gas, tar, benzol, hydrogen sulphide and ammonia are expelled, collected and recycled for other uses.
Coke:
Coke performs three main roles in a BF.Thermal role to provide energy to heat and melt the burden;Chemical role to act as a reducing agent and carburize pig iron.Mechanical role to maintain the permeability;
for upward flowing gases.for flow the liquids into hearth
OBS: Pulverized Coal Injected cannot assure permeability in blast furnace burden. The permeable bed is provided by the coke charged to the furnace
Preparation of the blast furnaceburden
Ironmaking Course
Mass Balance for Blast Furnace
Ironmaking Course
Carbon Consumption in the Blast Furnace(Thyssen Stahl AG, Germany)
Pig Iron Carburization 47 11,75
Reducing Gas Regeneration(C + CO2 = 2CO)
100 25,00
Burden Sensible Heat+ Thermal Losses
253 63,25
FUNCTIONCARBON
CONSUMPTION (kg/t HM)
(%)
Total 400 100
Basis : 400 kg C /t , Without PCI
Ironmaking Course
Main Mechanism of Fines Generation on Ironmaking
MECHANICAL STRENGTHRelated to amount of finesamount of fines generated by mechanical force (handling)
DECREPITATIONRelated to amount of finesamount of fines generated by thermal shock
DEGRADATION UNDER REDUTIONRelated to amount of finesamount of fines generated by gas chemical reactions
Ironmaking Course
PROPERTIES OF IRON ORE AND METALLURGICAL COAL AND COKE
Physical PropertiesPhysical
Properties
Chemical PropertiesChemical Properties
Metallurgical And Thermal
Properties
Metallurgical And Thermal
Properties
• Chemical composition: Fe, SiO2, Al2O3, Mn, S, P, Alkalis
• Loss of Ignition (LOI)• Moisture
• Size distribution• Average mean size• Porosity• Mechanical strength
• Mineralogical composition• Microstructure• Crystal size• Morphology• Softening and melting properties • Reduction disintegration
properties
• Chemical composition: Fe, SiO2, Al2O3, Mn, S, P, Alkalis
• Loss of Ignition (LOI)• Moisture
• Size distribution• Average mean size• Porosity• Mechanical strength
• Mineralogical composition• Microstructure• Crystal size• Morphology• Softening and melting properties • Reduction disintegration
properties
IRON OREIRON ORE COAL / COKECOAL / COKE
• Chemical composition: fixed C,ashes, S, P and alkalis
• Macerals: Volatile matter• Replacement ratio• Moisture
• Size distribution• Mean size• Bulk density• Porosity• Mechanical strength
• Combustibility • Mineralogical composition• Microstructure• Crystal size• Morphology• Coke Strength after Reaction• Reactivity
• Chemical composition: fixed C,ashes, S, P and alkalis
• Macerals: Volatile matter• Replacement ratio• Moisture
• Size distribution• Mean size• Bulk density• Porosity• Mechanical strength
• Combustibility • Mineralogical composition• Microstructure• Crystal size• Morphology• Coke Strength after Reaction• Reactivity
Ironmaking Course
COKE / COAL PROPERTIES TO GUARANTEEHIGH BLAST FURNACE PERMEABILITY
• Physical Properties of the Coke and Coal• Narrow size distribution range• High mechanical strength. • Lower blast momentum in raceway
• Lower volatile matter coal injection• Metallurgical properties
• High Coke Strength after Reaction (CSR)• Low ash content to promote lower slag rate
COKE / COAL PROPERTIES TO GUARANTEEHIGH BLAST FURNACE PERMEABILITY
• Physical Properties of the Coke and Coal• Narrow size distribution range• High mechanical strength. • Lower blast momentum in raceway
• Lower volatile matter coal injection• Metallurgical properties
• High Coke Strength after Reaction (CSR)• Low ash content to promote lower slag rate
MAIN DRIVER: HIGHER PERMEABILITYMAIN DRIVER: HIGHER PERMEABILITY
HIGH PRODUCTIVITY ON BLAST FURNACE
BURDEN (Iron Ore) PROPERTIES TO GUARANTEE HIGHER BLAST FURNACE PERMEABILITY• Physical Properties of the Burden
• Narrow size distribution range• Good mechanical strength and low fine
• Metallurgical properties• Low swelling• Good softening and melting properties• Low reduction disintegration properties
• Lower gangue to decrease the slag rate• Lower lump ore rate; higher pellet and sinter
BURDEN (Iron Ore) PROPERTIES TO GUARANTEE HIGHER BLAST FURNACE PERMEABILITY• Physical Properties of the Burden
• Narrow size distribution range• Good mechanical strength and low fine
• Metallurgical properties• Low swelling• Good softening and melting properties• Low reduction disintegration properties
• Lower gangue to decrease the slag rate• Lower lump ore rate; higher pellet and sinter
HIGH
PERMEABILITY
AND
PRODUCTIVITY
BLAST
FURNACE
HIGH
PERMEABILITY
AND
PRODUCTIVITY
BLAST
FURNACE
Ironmaking Course
COKE AND COAL PROPERTIES FOR GOODQUALITY AND LOW PRODUCTION COST
Physical Stability • High mechanical strength and high yield.
• Metallurgical properties• High Coke Reactivity (CRI)• High replacement ratio of the coal injection.
• Low ash, P, and S content.• High Injection rate (PCI)
COKE AND COAL PROPERTIES FOR GOODQUALITY AND LOW PRODUCTION COST
Physical Stability • High mechanical strength and high yield.
• Metallurgical properties• High Coke Reactivity (CRI)• High replacement ratio of the coal injection.
• Low ash, P, and S content.• High Injection rate (PCI)
MAIN DRIVER: LOWER CONSUMPTION AND GOOD CHEMICAL COMPOSITIONMAIN DRIVER: LOWER CONSUMPTION AND GOOD CHEMICAL COMPOSITION
GOOD HOT METAL QUALITY AND LOW COST
METALLIC BURDEN PROPERTIES FOR GOOD QUALITY AND LOW PRODUCTION COST
• Physical Properties of the Burden• Low fines generated and high yield
• Metallurgical properties• Low reduction disintegration properties
• Low S and P• Lower gangue, to decrease the slag rate• Higher lump ore rate
METALLIC BURDEN PROPERTIES FOR GOOD QUALITY AND LOW PRODUCTION COST
• Physical Properties of the Burden• Low fines generated and high yield
• Metallurgical properties• Low reduction disintegration properties
• Low S and P• Lower gangue, to decrease the slag rate• Higher lump ore rate
HIGH HOT
METAL
QUALITY
AND LOW
PRODUCTION
COST
HIGH HOT
METAL
QUALITY
AND LOW
PRODUCTION
COST
* A method to produce high reactivity and strength coke is being investigating by use Ca as catalyze elements* A method to produce high reactivity and strength coke is being investigating by use Ca as catalyze elements
Ironmaking Course
Lump Ore and Metallic Burden Evaluation
Sample degradation during heating on the blast furnace
Decrepitation Test
Tumbler Test ( ISO – 3271) Fine generation due to transfer/drops and abrasion
Reduction Test (ISO 7215/JIS M8713)Evaluate the reducibility of the sample
RDI Test (Reduction Degradation Index - ISO 4696-2)Mechanical strength of reduced sample
MLT Test (Midrex Linder Test)Dynamic reduction to evaluate metallization and degradation
Classify ores into several grades
Chemical analysis
Ironmaking Course
GasGas
SlagLiquid Metal
200
500a
800 900
a1000 1100
a1300 1400
a1600
2000
1400a
1500
Chemical Analysis
Size Distribution
Tumbler Test
Decrepitation
Disintegration
Reducibility
Softening
Melting And Dripping
Blast Furnace
Ore and Metallic Burden Evaluation
Ironmaking Course
REQUIRED PROPERTIES FOR BLAST FURNACE METALLIC CHARGE
BLAST FURNACE INSIDE
Zone Phenomenon Coke
Requered Properties
Sínter Pellet Ore
Granular Pre-heatingReduction
Softening and Melting
Softening and Melting
Gaseous Flow Redistribution
High Temperature Properties
Hearth
Raceway
DesulfurizationS/M Separation
Combustion
Dripping DrippingCarburization
Melting Characteristics
Primary metal behaviour
RDI SwellingDecrepitation
RDICSR/CSI
Reduticibility
Size Distribution
Resistance Resistance
Resistance and
adherent fines
Resistance
Reactivity
Ironmaking Course
INITIAL QUESTIONS
What do you understand as softening and melting?
What do you understand as the cohesive zone?
Ironmaking Course
Blast Furnace Cross Section: Emphasis to Softening & Melting Zone
PERMEABLE REGIONS
ORECOKE
FUSING IRON AND SLAG
PERMEABLE COKE SLITS
ACTIVELOOSE-PACKED
COKE BED
COMPACT
TUYERE
WALLCENTRE
GAS LINES
COHESIVE ZONE
High heat consumption region, where is accomplished:
The greatest part of iron oxides reduction
Metal and slag melting
Boudouard reacion takes place
High thermal gradient region
High pressure drop
Have a strong effect in the gas distribution
Ironmaking Course
Importance of Softening & Melting Zone
Dis
tânc
efr
om tu
yere
leve
l
Pressure (BAR)
2,0 2,5 3,0 3,5 4,0
Pressure drop in Pressure drop in the granular zonethe granular zone
Pressure drop in the Pressure drop in the softening & melting softening & melting
zonezone
Pressure drop Pressure drop in the tuyeresin the tuyeres
(70%)(70%)(15%)(15%) (15%)(15%)
HIGH PCI OPERATION
HIGH PRODUCTIVITY OPERATION
ACTIONS HAS TO BE TAKEN TO RESTORE THE BED
PERMEABILITY IN THIS RESTRICTIVE CONDITIONS
RESTRICTIONS FACTORS TO PERMEABILITY
Ironmaking Course
Softening Start Temperature Ts
Final Melting Temperature Te
∆ Temperature (Te-Ts)
Dripping Start Temperature Td
Reduction degree at 1100 °C R1100
Reduction Degree at Ts Rs
Accumulated pressure loss S value
Maximum Pressure Loss ∆ Pmax
TEST SUMMARY
Ironmaking Course
RIReduction index at 900ºC
R1000Reduction index at 1000ºC
R1100Reduction index at 1100oC
R1200Reduction index at 1200oC
S(S’) valueIntegration of pressure drop with respect to temperature(or time)
Ts200Start of pressure dropover 200mmH2O
Te200End of pressure dropover 200mmH2O
TdStart of dripping of metal or slag
∆T Te200-Ts200
CORRELATION BETWEEN INDEXES AND THE BLAST FURNACE
Ironmaking Course
Upper Heater Power: 45 kW
Maximum T: 1600°C
Lower Heater Power: 55 kW
Maximum T: 1700°C
Heating Rate:
Upper: 5°C/min > 800°C
Lower: 10°C/min > RT
Input Gas:
N2 (22.7 NL/min)
CO ( 9.9 NL/min)
CO2 ( - NL/min)
H2 ( 1.4 NL/min)
Shrinkage and Pressure
Drop Measurement
INDUSTRIAL TESTING EQUIPMENT - VALE
Coke (20 mm)
(20mm)
(70mm)
(20 mm)
MetallicBurden
Load
Load
Coke
Ironmaking Course
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
90,0
100,0
800 900 1000 1100 1200 1300 1400 1500 1600Temperature (°C)
Shrin
kage
(%)
0
1000
2000
3000
4000
5000
6000
Pres
sure
Dro
p (m
mH
2O)
Shrinkage
Pressure Drop
Ts: 1243°C Te: 1473°C S: 59.51 kg.°C/cm2 dPmax: 5419 mmH2O
TYPICAL RESULTS
Softening Melting
Cohesive Zone
Ironmaking Course
To provide solution in metallic => geo-metallurgy approach
Vale’s Technical Support to CustomersTechnical Methodology
Geological and mineralization
processes
Variabillity and ore types
Ore dressing behaviour
Characteristics and product quality
Behaviour in agglomeration and
metallurgic processes
Ironmaking Course
Lump
PelletsSinter Plant
SinterSinterfeed
Pig iron
BF
Steel
BOF
Stee
l Mill
sPi
lot P
lant
s
Pellet feed
Pelletizing
Para
met
ers
ChemicalPhysicalMetallurgicalMineralogical
ProductivityFuel consumptionProduct characteristics
Reduction indexesCohesive zone properties Permeability of burdenInteraction coke/metallic burden
Sinterização Piloto
Sintering pot
Pelotização Piloto
Forno de Amolecimento & Metallurgical testsPelletizing pot
Softening and meltingfurnace
Characterization
Chemical Analysis
Vale’s Technical Support to CustomersPhysical Simulation (1)
Ironmaking Course
Coke oven
Sintering
BF
FEA
Casting
DRIDirect reduction
BOF
Steel
Hot Metal
Pelletizin
LUMP
Rolling
Global thermal balance
Operations covered by mathematicalmodels at Vale
Vale’s Technical Support to CustomersNumerical Simulation (1)
Ironmaking Course
CFD Model considers:
Fluid and solid flows
Burden distribution
Softening and melting of burden components
Void fraction inside furnace
Temperature dependence of kinetic parameters
Heat and mass balances
Blast Furnace Fluid-dynamic Model(CFD)
Outputs:
Different operational practices
Productivity
Coke rate
Position and thickness of cohesive zone
Operation with high PCI
Environmental aspects 63% Sínter27% Pelotas10% Granulado
63% Sínter27% Pelotas10% Granulado
Vale’s Technical Support to CustomersNumerical Simulation (2)
Ironmaking Course
Simulation motto: “Operate a virtual Blast Furnace”
Increase production ?
Increase thermal reserve ?
reduce coke consumption?
increase PCI ?
Reduce hot metal cost ?
Unstable Stable response
Need for
model/operator
interaction
CFD Operator
Vale’s Technical Support to CustomersNumerical Simulation (3)
Blast Furnace Fluid-dynamic Model(CFD)
Ironmaking Course
Vale’s Technical Support to CustomersNumerical Simulation (4)
Ironmaking Course
Lump
PelletsSINTERING
Sinter
Sinter Feed
PIG IRON
BF
STEEL
BOF
Sintering Neural Network Model
Prediction of sintering parameters and product
BOF model
Mass and heat balance of refining operations to calculate steel costs and quality
Optimization of iron ore mix (linear programming)
Optimum iron ore mix to minimize pig iron costs and/or slag volume in BF
Computational Fluid Dynamic Model
BF inner state predictions
Stee
lmak
ing
chai
n
PHYSICAL SIMULATION
Pelletizing pilot plant
Sintering pilot plant
BF pilot plant
Characterization facilities
Num
eric
al s
imul
atio
n Ph
ysic
al s
imul
atio
n
CVRD products characteristics
Vale’s Technical Support to CustomersPhysical and Numerical Simulation
Ironmaking Course
Knowledge
StrategiesGeneration of Models
INFO Treatment(SIMULATION)
IntelligenceBuild-uo Data Analysis
Physical SimulationNumeric Simulation
Client Situation
Operational Data
INFO
Data Mining
Organizeand Process
INFOrmation Generation(Data Base)
Technical Visits
Data Base Structureand classification
Value in Use (VIU)Concept (1)
Ironmaking Course
Thanks for your attention!!!