Blast Furnace Ironmaking: Analysis, Control, and Optimization uses a fundamental first principles approach to prepare a blast furnace mass and energy balance in ExcelT. Robust descriptions of the main equipment and systems, process technologies, and best practices used in a modern blast furnace plant are detailed. Optimization tools are provided to help the reader find the best blast furnace fuel mix and related costs, maximize output, or evaluate other operational strategies using the ExcelT model that the reader will develop.
The first principles blast furnace ExcelT model allows for more comprehensive process assessments than the 'rules of thumb' currently used by the industry. This book is suitable for undergraduate and postgraduate science and engineering students in the fields of chemical, mechanical, metallurgical and materials engineering. Additionally, steel company engineers, process technologists, and management will find this book useful with its fundamental approach, best practices description, and perspective on the future.
- Provides sample problems, answers and assignments for each chapter
- Explores how to optimize the blast furnace operation while maintaining required temperatures and gas flowrates
- Describes all major blast furnace equipment and best practices
- Features blast furnace operating data from five continents
Please Note: This is an On Demand product, delivery may take up to 11 working days after payment has been received.
1. The iron blast furnace process 2. Inside the blast furnace 3. Making steel from molten blast furnace iron 4. Introduction to the blast furnace mass balance 5. Introduction to the blast furnace enthalpy balance 6. Combining mass and enthalpy balance equations 7. Conceptual division of the blast furnace
bottom segment calculations 8. Bottom segment with pulverized carbon injection 9. Bottom segment with oxygen enrichment of blast air 10. Bottom segment with low purity oxygen enrichment 11. Bottom segment with CH4(g) injection 12. Bottom segment with moisture in blast air 13. Bottom segment with pulverized hydrocarbon injection 14. Raceway flame temperature 15. Automating matrix calculations 16. Raceway flame temperature with pulverized carbon injection 17. Raceway flame temperature with oxygen enrichment 18. Raceway flame temperature with CH4(g) injection 19. Raceway flame temperature with moisture in blast air 20. Top segment mass balance 21. Top segment enthalpy balance 22. Top gas temperature calculation 23. Top segment calculations with pulverized carbon injection 24. Top segment calculations with oxygen enrichment 25. Top segment mass balance with CH4(g) injection 26. Top segment enthalpy balance with CH4 injection 27. Top gas temperature with CH4 injection 28. Top segment calculations with moisture in blast air 29. Bottom segment calculations with natural gas injection 30. Raceway flame temperature with CH4(g) injection 31. Top segment calculations with natural gas injection 32. Bottom segment slag calculations
Ore, fluxes, and slag 33. Bottom segment slag calculations
With excess Al2O3 in ore 34. Bottom segment slag calculations 35. Bottom segment calculations
Reduction of SiO2 36. Bottom segment calculations
Reduction of MnO 37. Bottom segment calculations with pulverized coal injection 38. Bottom segment calculations with multiple injectants 39. Raceway flame temperature with multiple injectants 40. Top segment calculations with multiple injectants 41. Top segment calculations with raw material moisture 42. Top segment with carbonate fluxes 43. Top charged steel scrap 44. Top charged direct reduced iron 45. Bottom segment calculations with H2(g) injection 46. Top segment calculations with H2(g) injection 47. CO(g) injection into bottom and top segments 48. Introduction to blast furnace optimization 49. Blast furnace optimization case studies 50. Blast furnace rules of thumb 51. The blast furnace plant 52. Blast furnace proper 53. Blast furnace refractory inspection technologies 54. Blast furnace ferrous burden preparation 55. Metallurgical coke
A key to blast furnace operations 56. Blast furnace fuel injection 57. Casting the blast furnace 58. Blast furnace slag 59. Burden distribution
Mr. Ian Cameron is the principal metallurgist, Ferrous for the Pyrometallurgy Sector Practice at Hatch Ltd., Ontario, Canada. He services a global clientele, solving technical and business challenges throughout the iron and steel value chain starting from the main raw materials. Ian has more than 35 years of experience including 20+ years as a consulting engineer for Hatch and previously Corus Consulting/Hoogovens Technical Services. He brings extensive experience in process technology, blast furnace operations, technology transfer, commissioning and training to his steel industry clients. This includes forecasting future raw material usage patterns for major mining houses, developing new blast furnace related technologies, designing new steelworks and solving acute operational problems including plant emergencies. Ian holds Bachelor and Master's Degrees in Metallurgical Engineering from McGill University, Montreal, Canada and is a licensed Professional Engineer in Ontario, Canada.
Dr. Mitren Sukhram is a senior process engineer in the Pyrometallurgy Sector Practice at Hatch Ltd. He works on all aspects of blast furnace ironmaking including reline planning, techno-economic assessments, campaign life assessment/extension, and operational support for blast furnaces located around the world. More recently, Mitren has focused on developing innovative technologies to improve blast furnace productivity and reduce greenhouse gas emissions. Mitren is a graduate from the University of Toronto, Toronto, Canada where he completed Bachelor, Master's and PhD degrees in Material Science and Engineering. In his PhD studies, Mitren developed a novel sensor that measured velocity patterns in liquid metals. His areas of expertise include thermodynamics, heat, mass, and momentum transfer in pyrometallurgical processes. Mitren is a licensed Professional Engineer in Ontario, Canada.
Kyle Lefebvre is a process engineer in the Pyrometallurgy practice at Hatch Ltd. His work includes process modelling and logistical simulations in the iron and steel industry. Kyle has worked on new steel works design, and he has assessed of a wide range of processes in the iron and steelmaking value chain. Kyle has visited several blast furnaces in North America to perform furnace inspections and to improve plant operations. Kyle holds a Bachelor and Master's degrees in Applied Science and Chemical Engineering from McMaster University, Hamilton, Ontario. Kyle is a licensed professional engineer in Ontario, Canada.
William Davenport is an Emeritus Professor at the University of Arizona, United States. He has taught and consulted for more than 50 years. He has authored 6 metallurgical text books, most of which have gone into multiple English and foreign language editions. He has been interested in iron and steel since he worked in the industry in the 1960's. Together with Dr. John G. Peacey, Professor Davenport co-authored a previous book, The Iron Blast Furnace, Theory and Practice, Elsevier 1979. Professor Davenport has visited iron and steel plants around the world and in 2017, he visited several major Japanese blast furnace plants.