BLAST FURNACE REPORT

1. Introduction

A blast furnace is a metallurgical furnace used for smelting to produce industrial metals,
generally iron. It operates by using a blast of hot air introduced under pressure to combust fuel
(typically coke), thereby reducing iron ore to molten iron. This technology plays a vital role in
the steel-making process and has been the backbone of heavy industries for centuries.

BLAST FURNACES

What is a Blast Furnace? BF is a counter current heat and mass exchanger, inwhich solid raw
materials are charged from the top of the furnace and hot blast is sent through the bottom via
tuyeres. The heat is transferred from the gas to theburden and oxygen from the burden to the
gas. Gas ascends up the furnace while burden and coke descend down through the furnace. The
counter current nature of the reactions makes the overall process an extremely efficient one.

In the blast furnace process iron ore and reducing agents (coke, coal) are
transformed to hot metal, and slag is formed from the gangue of the ore burden and the ash of
coke and coal. Hot metal and liquid slag do not mix and remain separate from each other with
the slag floating on top of the denser iron. The iron can then be separated from the slag in the
cast house. The other product from the Blast Furnace is dust laden blast furnace gas, which is
further cleaned in the gas cleaning plant and is used as a fuel all over the plant.

Blast Furnace constructional features:

A blast furnace has a typical conical shape. The sections from top down are:

> Throat, where the burden surface is.

> The shaft or stack, where the ores are heated and reduction starts.

> The bosh parallel or belly and

> The bosh, where the reduction is completed and the ores are melted down. The hearth, where
the molten material is collected and is cast via the tap hole
MACHINING ASSEMBLY & RE-ENGINEERING SERVICES-1

( MARS-1).

MARS-1 has a vital role to play in maintaining the plant equipment so for as it supplies the
bulk of spare parts required by the various units. It acquires an added significance by virtue of
the finishing line of manufacturing activities of engineering shop . The product mix so
arranged so as to meet the demand of both heavy and small spares. The shop is housed in three
machining bays, 21 meters x182 meters each with an assembly bay of 24 meters x 96 meters .A
total of 196 machine –tools are engaged in direct production of spares, where- as the remaining
contribute indi- rectly towards shop production. Apart from these, there are 12 Heat
Treatment / Heating furnaces 22 material handling equipment (cranes,jib cranes transfer cars).
The Annual production plan for MARS-1 during 2007-2008 is 6,40,000 credit hours.

MAIN ACTIVITIES:-

Function wise MARS-1 carries out the following activities:

1. Manufacture of spares, changables, tools, tackles etc. Required for maintenance and
operation of various departments.

2. Overhauling and repair of equipment sub - assemblies to the extent of those that can be
transported to MARS-1.

3. Reclamation of worn-out spares .

4. Repair of certain equipment at site-especially where machining at site is required.

5. Manufacturing and modification of equipment / spares for development work from the point
of view of import substitution,cost reduction ,etc.
 BLOOMING & BILLET MILL

Blooming & Billet Mill popularly known as "Mother Mill", is a primary mill designed to roll
2.5 MT/ Annum of ingots into semies in the form of blooms & billets. A two high reversing
blooming mill and 12 stands continuous billet mill are part of this department. The 1150mm
two high reversing Blooming Mill is designed to roll steel ingots into blooms for Continuous
Billet Mill and Rail & Structural Mill. Average weight of steel ingots which are used for
rolling is 8 to 9 Ton.

BLOOMING MILL

The heated ingot are placed on the ingot buggy (two ingots at a time) by means of tongs crane
which delivers it on to the receiving roller table of Blooming Mill.The Blooming Mill is a 2-
High horizontal stand, equipped with individually driven rolls. Each roll of the Blooming Mill
is driven by 930 V, 8000 KW, 0-20-80 rpm motor.

Length of Roll - 2800 mm

Dia. of Roll - 1150 mm (Min.1100mm & Max.1180mm)

The Mill can roll square and rectangular blooms and also narrow width slab. Common Sizes of
Blooms and Narrow Width Slabs

i) 320 x 320 mm

ii) 265 x 340 mm

iii) 260 x 300 mm

iv) Shaped blooms for Beam-450mm & Beam-600mm

v) Narrow Width Slab 200 x 320 mm

vi) Narrow Width Slab 200 x 420 mm

BILLET MILL

The Billet Mill has been designed to roll billets from blooms of cross section 325x325 sq.mm
in 6 to 12 passes depending on cross section of billets to be produced in the Mill. The capacity
of the Mill was designed to roll 15,01,000 Tonns/Year. But with modified output size of billets
the mill is now capable of rolling to million tones per year.

The Mill consists of 12 working stands arranged in three groups.

a. The First group contains Two 2-High Horizontal stands with a 90 deg. tilter in between.
These stands are equipped with rolls of diameter 1000mm and length 1200mm.

b. The Second group called the roughing group contains 4 stand - 2 each of Horizontal and
Vertical stands arranged alternately. These stands are equipped with rolls of diameter 700mm.

c. The Third group called the finishing group located after the transfer table contains 6 stands -
3 horizontal and 3 vertical stands arranged alternately. These stands are equipped with rolls of
diameter 500mm.

SECTION OF BILLETS ROLLED ARE

1. 150 x 150 mm 2. 110 x 110 mm

3. 105 x 105 mm 4. 100 x 100 mm

5. 90 x 90 mm
 WIRE ROD MILL

The 4 strand 250mm continuous Wire Rod Mill, commissioned on September 1 1967, was
designed to roll 6, 7, 8, 10mm diameter wire rods from square billets of 80mm x 80mm cross
section (of length 11 to 11.8 meters) with rated capacity of 4,00,000 T per annum. The billet
size was further enhanced to 85 mm2, 90 mm2, 100 mm2, 105 mm2 to improve in coil weight
from 540 Kgs. to 930 Kgs. After the revamping of Right Side, sections 5.5 - 12 mm dia. wire
rods are rolled in B , C&D strands, whereas 8mm & 10mm are rolled on left side (A strand).

BRIEF DESCRIPTION OF THE MILL

Inspected billets are fed on the charging grate of the furnace by magnetic finger cranes. The
billets are fed one by one to the furnace, through roll table and draw-in- roller mechanism.
Billets are moved into the furnace by means of pushers at the charging end. Soaked billets are
ejected out by means of Ejector Ram from the discharging end.

The reheating furnace of the size 18Mx 12M is having 28 burners, which includes 14 in
the heating zone and 14 in the soaking zone. Mixed (Coke Oven & Blast Furnace) gas with
calorific value of 1800 K Cal/Cum is used in the furnace as fuel. Capacity of the furnace is
120T/Hr. Gas and air is preheated to 250°c and 450°c in metallic and ceramic recuperators
respectively.

The roughing group consists of nine horizontal stands in which combined drive is
provided for stands 2-3 and 4-5; whereas stands 1, 6, 7, 8 and 9 are individually driven. All the
drives are controlled by thyristor converter.

Flying Shear is provided after stand no. 9 for front-end cutting & cobble cutting. First
intermediate group has 6 horizontal stands, out of which stand No. 12 & 13 are not being used.
Stand No. 10 & 11/14 & 15 are used for rolling on all the strands. After stand No. 15, the Mill
is divided in four strands, old line (A) and Modernised line (B,C&D).
Here's a complete report on Blast Furnace suitable for BTech engineering projects. It includes
key sections like Introduction, Working, Components, Applications, Advantages,
Disadvantages, and References. You can copy it into a Word document or let me know if you'd
like a downloadable version in .docx or .pdf.

COMPONENTS USED IN THIS PROJECT

FLAME SENSOR

For a fire detection system like FireSentinel, the most commonly used fire sensor is the flame
detector sensor. Here are the details about this type of sensor:

1. **Sensor Type**: Flame detector sensors are designed to detect the presence of flames or
fire by sensing the electromagnetic radiation emitted by the flames.
2. **Working Principle**: Flame detector sensors typically use one of the following
principles:

a. **Infrared (IR) Sensing**: These sensors detect the infrared radiation emitted by flames,
which have a specific wavelength range in the IR spectrum.

b. **Ultraviolet (UV) Sensing**: Some flame detectors are designed to sense the ultraviolet
radiation emitted by flames, which is not present in most other light sources.

c. **Combined IR/UV Sensing**: Advanced flame detectors combine both IR and UV

sensing mechanisms to improve accuracy and reduce false alarms.

3. **Sensor Components**:

a. **IR or UV Sensor Element**: The core component is a specialized sensor element that is
sensitive to the infrared or ultraviolet radiation emitted by flames.

b. **Optical Filter**: An optical filter is often used to filter out unwanted wavelengths and
focus on the specific wavelengths associated with flames.

c. **Signal Processing Circuit**: The sensor output is processed by a circuit that amplifies
and filters the signal to distinguish between actual flames and other sources of IR or UV
radiation.

4. **Output Signal**: Flame detector sensors typically provide a digital output signal,
indicating the presence or absence of a flame. Some sensors may also provide an analog output
proportional to the intensity of the detected flame.

5. **Sensitivity and Range**: The sensitivity and detection range of flame detectors can vary
depending on the sensor model and design. Some sensors can detect flames from several
meters away, while others may have a shorter detection range.

6. **Advantages**:
 a. **Early Fire Detection**: Flame detectors can detect fires at an early stage, before smoke
or heat becomes significant, allowing for a quicker response.

b. **Immunity to Dust and Humidity**: Unlike smoke detectors, flame detectors are not
affected by dust or humidity, reducing the chances of false alarms.

7. **Disadvantages**:

a. **Line-of-Sight Requirement**: Flame detectors typically require a clear line-of-sight to

the flame, which can be obstructed by objects or walls.

b. **Limited Coverage Area**: Each flame detector has a limited coverage area, and
multiple detectors may be required to monitor a larger area effectively.

8. **Interfacing**: Flame detector sensors can be easily interfaced with the NodeMCU using
digital input pins or analog input pins, depending on the sensor's output type.

9. **Power Requirements**: Most flame detector sensors operate within the voltage range of
5V to 12V DC, making them compatible with the NodeMCU's power supply.

When integrating a flame detector sensor into the FireSentinel system, it's essential to follow
the manufacturer's instructions for proper installation, positioning, and calibration.
Additionally, combining flame detectors with other types of fire sensors, such as smoke
detectors or heat detectors, can improve the overall reliability and accuracy of the fire detection
system.
 W1209
TEMPERATURE CONTROL SWITCH
Model HCTHER0006
Condition New
The W1209 is an incredibly low cost yet highly functional thermostat controller. With this
module (HCTHER0006) you can intelligently control power to most types of electrical device
based on the temperature sensed by the included high accuracy NTC temperature sensor.
Although this module has an embedded microcontroller no programming knowledge is
required. 3 tactile switches allow for...

The W1209 is an incredibly low cost yet highly functional thermostat controller. With this
module (HCTHER0006) you can intelligently control power to most types of electrical device
based on the temperature sensed by the included high accuracy NTC temperature sensor.
Although this module has an embedded microcontroller no programming knowledge is
required. 3 tactile switches allow for configuring various parameters including on & off trigger
temperatures. The on board relay can switch up to a maximum of 240V AC at 5A or 14V DC
at 10A. The current temperature is displayed in degrees Centigrade via its 3 digit seven
segment display and the current relay state by an on board LED.

Temperature Control Range: -50 ~ 110 C

Resolution at -9.9 to 99.9: 0.1 C
Resolution at all other temperatures: 1 C
Measurement Accuracy: 0.1 C
Control Accuracy: 0.1 C
Refresh Rate: 0.5 Seconds
Input Power (DC): 12V
Measuring Inputs: NTC (10K 0.5%)
Waterproof Sensor: 0.5M
Output: 1 Channel Relay Output, Capacity: 10A
Power Consumption
Static Current: <=35mA
Current: <=65mA

Environmental Requirements
Temperature: -10 ~ 60 C
Humidity: 20-85%

Dimensions
48mm x 40mm x 14mm

Settings Chart
Long press the “SET” button to activate the menu.

Code Description Range Default Value

P0 Heat C/H C
P1 Backlash Set 0.1-15 2
P2 Upper Limit 110 110
P3 Lower Limit -50 -50
P4 Correction -7.0 ~ 7.0 0
P5 Delay Start Time 0-10 mins 0
P6 High Temperature Alarm 0-110 OFF

Long pressing +- will reset all values to their default

Displaying the current temperature:

The thermostat will display the current temperature in oC by default. When in any other mode
making no input for approximately 5 seconds will cause the thermostat to return to this default
display.

Setting the trigger temperature:

To set the trigger temperature press the button marked 'SET'. The seven segment display will
flash. You can now set a trigger temperature (in oC) using the '+' and '-' buttons in 0.1 degree
increments. If no buttons are pressed for approximately 2 seconds the trigger temperature will
be stored and the display will return back to the current temperature.

Setting the parameters:

To set any parameter first long press the 'SET' button for at least 5 seconds. The seven segment
display should now display 'P0'. This represents parameter P0. Pressing the '+' or '-' buttons
will cycle though the various parameters (P0 to P6). Pressing the 'SET' button whilst any of
there parameters are displayed will allow you to change the value for that parameter using the
'+' and '-' buttons (see below). When finished setting a parameter press the set button to exit
that option. If no buttons are pressed for approximately 5 seconds the thermostat will exit the
parameter options and will return back to the default temperature display.

Setting the cooling or heating parameter P0:

The parameter P0 has two settings, C and H. When set to C (default) the relay will energise
when the temperature is reached. Use this setting if connecting to an air-conditioning system.
When set to H the relay will de-energise when the temperature is reached. Use this setting if
controlling a heating device.

Setting the hysteresis parameter P1:

This sets how much change in temperature must occur before the relay will change state. For
example if set to the default 2oC and the the trigger temperature has been set to 25oC, it will
not de-energise until the temperature falls back below below 23oC. Setting this hysteresis helps
stop the thermostat from continually triggering when the temperature drifts around the trip
temperature.

Setting the upper limit of the thermostat parameter P2:

This parameter limits the maximum trigger temperature that can be set. It can be used as a
safety to stop an excessively high trigger temperature from accidentally being set by the user.

Setting the lower limit of the thermostat parameter P3:

This parameter limits the minimum trigger temperature that can be set. It can be used as a
safety to stop an excessively low trigger temperature from accidentally being set by the user.
Setting temperature offset correction parameter P4:
Should you find there is a difference between the displayed temperature and the actual
temperature (for instance if the temperature probe is on a long run of cable) you can make
minor corrections to the temperature reading with this parameter.

Setting the trigger delay parameter P5:

This parameter allows for delaying switching of the relay when the trigger temperature has be
reached. The parameter can be set in one minute increments up to a maximum of 10 minutes.

Setting the high temperature alarm parameter P6:

Setting a value for this parameter will cause the relay to switch off when the the temperature
reaches this setting. The seven segment display will also show '---' to indicate an alarm
condition. The relay will not re-energise until the temperature falls below this value. The
default setting is OFF.
2. Objective of the Project

 To understand the construction and working of a blast furnace.

 To study the chemical reactions taking place during iron extraction.
 To analyze the energy and material balance of the process.
 To evaluate environmental impacts and suggest mitigation methods.
3. Components of a Blast Furnace

Component Description
Throat Topmost part, where raw materials are charged.
Stack Tall section where preheating and partial reduction occurs.
Belly Widest part, facilitating smooth flow.
Bosh Bottom tapered portion where temperature is highest.
Hearth Bottom part where molten metal and slag collect.
Tuyeres Pipes that inject hot air blast.
Bustle Pipe Circular pipe surrounding the furnace, supplying air to tuyeres.
Slag Hole Outlet for waste slag.
Tap Hole Outlet for molten iron.
4. Raw Materials Used

 Iron Ore: Hematite (Fe₂O₃), Magnetite (Fe₃O₄)

 Coke: Acts as both fuel and reducing agent
 Limestone (CaCO₃): Acts as a flux to remove impurities
5. Chemical Reactions

a) Reduction of Iron Ore

Fe2O3 + 3CO → 2Fe + 3CO2

Fe3O4 + 4CO → 3Fe + 4CO2

b) Combustion of Coke

C + O2 → CO2
CO2 + C → 2CO

c) Formation of Slag

CaCO3 → CaO + CO2

CaO + SiO2 → CaSiO3 (Slag)

6. Working Process

1. Charging: Iron ore, coke, and limestone are charged from the top.
2. Pre-heating: Air is preheated and injected through tuyeres.
3. Combustion: Coke burns at the bottom, generating heat.
4. Reduction: Iron oxides are reduced to molten iron.
5. Separation: Molten iron and slag are collected and removed separately.
6. Discharge: Iron is tapped out and further processed in steel-making.
7. Output Materials (Elaborated)

🔹 Pig Iron

Pig iron is the primary output of a blast furnace and is a key intermediate in the steelmaking
process. It is characterized by a high carbon content (typically 3–5%), which makes it hard
and brittle. Along with carbon, pig iron contains traces of other elements such as:

 Silicon (Si) – adds brittleness and improves castability.

 Manganese (Mn) – helps remove oxygen and sulfur during smelting.
 Phosphorus (P) and Sulfur (S) – impurities that need to be removed during steel
production.

Pig iron is tapped from the blast furnace and either cast into molds (called pigs) or transferred
to a basic oxygen furnace for further refinement into steel.

🔹 Slag

Slag is the non-metallic waste product formed by the reaction between flux (like limestone)
and gangue (impurities in iron ore). It floats on top of the molten iron and is tapped off
separately. Despite being a by-product, slag has numerous industrial applications, including:

 As an aggregate in road construction.

 A component in cement and concrete production, improving strength and durability.
 In land reclamation and soil stabilization.
 In manufacturing insulation materials.

Slag management is crucial for the economic and environmental efficiency of the blast furnace
process.

8. Advantages of Blast Furnace (Elaborated)

✅ High Production Rate

Blast furnaces are capable of producing thousands of tons of pig iron per day. This high
throughput makes them ideal for meeting industrial-scale demands, particularly in countries
with large steel consumption.

✅ Economically Viable for Large-Scale Production

Due to economies of scale, the cost per ton of iron decreases significantly with increased
production. Once installed and operational, the blast furnace becomes a cost-effective option
for sustained iron production over long periods.

✅ Continuous Operation (24x7)

Unlike batch processes, the blast furnace is a continuous process, meaning it operates non-
stop for several months or even years (a "campaign") before requiring maintenance. This
results in consistent output and maximized efficiency.

✅ Energy-Efficient (with Modern Technology)

Modern blast furnaces use waste heat recovery systems, like Cowper stoves, to preheat the
air blast, reducing fuel consumption. Integration with top gas recovery turbines (TRTs) and
automation systems has further improved energy performance.

9. Disadvantages of Blast Furnace (Elaborated)

❌ High Carbon Emissions and Pollution

One of the most significant drawbacks of the blast furnace is the emission of large quantities
of CO₂, a greenhouse gas. Additionally, SOx, NOx, and particulate matter are released,
contributing to air pollution and climate change.

❌ High Initial and Maintenance Cost

Setting up a blast furnace involves massive capital investment for infrastructure, raw
materials handling, pollution control, and automation. Maintenance shutdowns, though
infrequent, are costly and time-consuming.
❌ Limited Flexibility

Blast furnaces are primarily designed to process iron ore to pig iron. They lack the flexibility
to adapt to different feedstocks or produce multiple metal types. This limits innovation in
product diversity.

❌ Unsuitable for Small-Scale Operations

Due to their size, cost, and operational requirements, blast furnaces are not viable for small or
medium enterprises. They are generally restricted to large steel plants and government-
supported industries.

10. Applications of Blast Furnace Output (Elaborated)

🏭 Steel Manufacturing

Pig iron is the primary input for steelmaking processes such as the Basic Oxygen Process
(BOP) or Electric Arc Furnace (EAF). It is refined to remove excess carbon and impurities to
produce different grades of steel used in:

 Construction
 Automotive industry
 Shipbuilding
 Infrastructure and bridges

Foundries and Casting Industries

Pig iron is also directly used in cast iron production, where its high carbon content is
beneficial. Foundries melt pig iron and cast it into machine parts, pipes, engine blocks, and
decorative items.

Slag Applications

Blast furnace slag is an eco-friendly by-product that finds use in:

 Road base and asphalt pavement

  Cement manufacturing (as ground granulated blast furnace slag - GGBS)
 Soil stabilization and backfilling
 Concrete blocks and bricks

This not only reduces industrial waste but also lowers the carbon footprint of construction
materials.

11. Future Scope

 Integration with Carbon Capture and Storage (CCS) to reduce emissions.

 Use of hydrogen as a reducing agent (Green steel production).
 Adoption of Industry 4.0 for real-time process monitoring and automation.
12. Conclusion

The blast furnace remains an essential part of modern metallurgical engineering.

Understanding its working provides insight into high-temperature chemical engineering,
thermodynamics, and sustainable industrial practices. This project offers engineering students a
foundation for innovations in metallurgical process improvements and energy-efficient steel
manufacturing.

The blast furnace stands as a monumental achievement in the field of metallurgical and process
engineering. It exemplifies how principles of thermodynamics, chemical kinetics, material
science, and fluid mechanics converge to enable large-scale metal extraction. In this project,
we explored not just the basic operation of a blast furnace but also delved into its internal
structure, material flow, and the complex chemical reactions that occur at high temperatures.

Through the analysis of each component and their roles—from tuyeres to the hearth—we have
gained insight into the efficiency of the furnace and the importance of maintaining specific
thermal and chemical conditions. We also studied the environmental challenges such as CO₂
emissions and the need for slag disposal. Despite these concerns, the blast furnace continues to
be a preferred method due to its ability to produce large quantities of iron economically and
efficiently.

Looking ahead, the role of blast furnaces in sustainable metallurgy is being questioned and
simultaneously innovated. New research is focusing on lowering the carbon footprint using
hydrogen-based reduction, renewable energy integration, and carbon capture technologies. As
engineering students, understanding these foundational processes equips us to contribute
toward greener and more efficient metallurgical solutions.

This project has not only enhanced our technical understanding but also developed our
analytical thinking towards real-world industrial applications and sustainability.
13. References

1. Ghosh, A., & Chatterjee, A. (2008). Ironmaking and Steelmaking: Theory and
Practice. Prentice-Hall of India.
– Comprehensive textbook on iron and steel production processes, with practical
industry case studies.
2. Ray, H. S. (1991). Introduction to Iron and Steelmaking. PHI Learning Pvt. Ltd.
– Offers in-depth understanding of the blast furnace process and related
thermodynamics.
3. Biswas, A. K. (1981). Principles of Blast Furnace Ironmaking: Theory and Practice.
Cootha Publishing House.
– A detailed academic resource focusing exclusively on the blast furnace operation and
design.
4. National Programme on Technology Enhanced Learning (NPTEL) – Metallurgy
Video Lectures by IIT Madras.
– https://nptel.ac.in/courses/113104060
– A great source for visual understanding of industrial metallurgy processes.
5. World Steel Association – Ironmaking Process Overview and Sustainability Reports.
– https://worldsteel.org
– Provides statistical data and global trends in iron and steel manufacturing.
6. TATA Steel Technical Papers – Sustainable Ironmaking Processes.
– https://www.tatasteel.com/media
– Offers industrial innovations in reducing the carbon footprint of blast furnaces.
7. ScienceDirect Journal of Iron and Steel Research – Peer-reviewed articles on
advancements in blast furnace operations.
– https://www.sciencedirect.com/journal/journal-of-iron-and-steel-research
8. United Nations Industrial Development Organization (UNIDO) – Cleaner
Production in Iron and Steel Sector.
– Explores policies and technical guidance for reducing environmental impacts of
metallurgical industries.