Blast Furnace Ironmaking: Analysis, Control, and Optimization uses a fundamental first principles approach to prepare a blast furnace mass and energy balance in ExcelTM. 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 ExcelTM model that the reader will develop. The first principles blast furnace ExcelTM 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

The Iron Blast Furnace: Theory and Practice presents theoretical, experimental, and operational evidence about the iron blast furnace as well as a mathematical description of its operation. This book includes a set of equations that accurately describe stoichiometric and enthalpy balances for the process and which are consistent with observed temperatures and compositions in the furnace stack. These equations, which have been devised on the basis of the Rist approach, show the effects of altering any blast-furnace variable on the other operating requirements of the process. This monograph is comprised of 14 chapters and begins with a brief description of the blast-furnace process. The next chapter takes a look inside the furnace, paying particular attention to its behavior in front of the tuyères and the kinetics of the coke gasification reaction. The reader is then introduced to the thermodynamics and stoichiometry of the blast-furnace process; enthalpy balance for the bottom segment of the furnace; the effects of tuyères injectants on blast-furnace operations; and blast-furnace optimization by linear programming. A number of important variables covered by the equations are discussed, including hydrocarbon injection at the tuyères, oxygen enrichment of the blast, moisture, limestone decomposition, coke reactivity, and metalloid reduction. The effects of many of these variables are illustrated numerically in the text while others are demonstrated in sets of problems that follow each chapter. This text will be a valuable resource for metallurgists and materials scientists.

Typological, repetitive, at times oddly humorous, Bernd and Hilla Becher's photographs of industrial structures are, in their cumulative effect, profoundly moving. The Becher's serenely cool, disarmingly objective, and notoriously obsessive images of watertowers, gas tanks, grain elevators, blast furnaces, and mine heads have been taken over a period of almost thirty years, under overcast skies, with a view camera that captures each detail and tonality of wood, concrete, brick, and steel. Blast Furnaces represents a continuation of, but also a counterpoint to the Bechers' earlier book Watertowers. There basic functional elements were hidden or clothed in disguises, whereas the 256 duotone prints included here record a purely functional and exposed architecture, built to contain heat, pressure, and accumulations of gases and unhindered by any outside constraints. The blast furnace is the symbol of the steel industry. Like other building types which attract the Bechers, it is also an endangered industrial species. Essentially giant, cone-shaped circular stoves, blast furnaces dominate the cityscapes of Pittsburgh, Youngstown, and Birmingham much as religious structures dominated medieval cities. These photographs, taken between 1961 and 1989, convey the unique characteristics, physical complexity, and eerie presence in the landscape of blast furnaces in Great Britain, Belgium, France, Austria, Germany, and the United States. Bernd and Hilla Becher teach at the Dusseldorf Art Academy. They began their collaborative photographic enterprise in 1957, when they did a study of workers' houses in their native Germany. The Bechers follow in a distinguished line of German photographers that includes August Sander, Albert Renger-Patzsch, and Werner Manz, all of whom contributed in different ways to the definition of "objective" photography. A selection of their photographs is on view throughout 1990 at the Dia Art Foundation galleries in New York, and they will represent Germany in the 1990 Venice Biennale.

As ironmakers are well aware, it was only a few decades ago that the blast furnace was viewed as a strange 'black box'. Recently, however, various in-furnace phenomena have become the subject of serious scientific study, largely as the result of the 'dissection' of dead furnaces, together with the development of advanced monitoring and control techniques. In this way, a new frontier has been opened within the venerable domain of metallurgy. In the light of these new developments, the Committee on Reaction within Blast Furnaces was set up in March 1977 by the Joint Society ofIron and Steel Basic Research - a cooperative research organization of the Iron and Steel Institute of Japan (ISIJ), the Japan Institute of Metals (JIM) and the Japan Society for the Promotion of Science (JSPS). Consisting of twenty-six members and advisors drawn from the fields of academia and industry, this committee collected, discussed, and evaluated numerous papers during its five year commission. Particular attention was paid to the interpretation of findings drawn from the autopsy of dead furnaces, in the context of the live furnace state, and the correlation of data regarding cohesive zone configuration, level, and furnace performance. The results of this intense research activity are presented here in the hope that they will serve not only as a source of enrichment to the professional knowledge of researchers and operators, but also as textual material for graduate students in the field of metallurgy.

"This publication was and can be used as an introductory text for students of metallurgy as well as for blast furnace operators and management. The latter will benefit to solve operational problems and process optimization issues." --Book Jacket.

This unique book presents an in-depth analysis of all the emerging ironmaking processes, supplementing the conventional blast furnace method. Various processes for producing solid and liquid iron are discussed, including important features such as process outline, techno-economics, and process fundamentals. The present global status of each process is examined, projections for the future are made, and processes are compared. Beyond the Blast Furnace is valuable reading for process developers, because it gives them a complete picture of various process options. Conventional iron- and steelmakers as well as researchers and practitioners working in the area of alternative processes of ironmaking will also benefit from this ready reference. The book is an ideal text for undergraduate and postgraduate students in metallurgy.

Modern Blast Furnace Ironmaking – An Introduction (Fourth Edition, 2020) describes the principles of the blast furnace process. As a starting point, the blast furnace is seen as a simple iron ore melter, while gradually the physical, chemical and metallurgical background of the blast furnace process is clarified. The book focuses on the control of the process with respect to thermal control, gas flow control and casthouse operation. In this book, all essential process details are described and a special focus is on cost optimization by low coke rates and on management of the process in case of disturbances and upsets. The optimization of the blast furnace is not only based on “best practice transfer”, but also requires conceptual understanding why a measure works in some cases and not in other cases. In other words, operational improvement is not only based on know–how, but as well on know–why. This publication can be used as an introductory text for students of metallurgy as well as for blast furnace operators and management.

This book focuses on how to keep blast furnaces running stably and smoothly with low consumption and long operating life spans. Assessing and adjusting blast furnace performance are key to operation. The book describes in detail cases of both successful and failed blast furnace operation. It also demonstrates various phenomena and “symptoms” in the smelting process that have rarely been studied before, e.g. abnormal gas distribution, bending loss of tuyere, slag crust fall-off, blast furnace thickening, and hearth accumulation. As such, it will help readers understand internal phenomena in blast furnaces, providing a basis for developing intelligent control and management systems.

This book presents the results of extensive research on the mathematical modelling of the blast furnace process. It describes the mathematical models utilised, providing insights into two-dimensional models of gas dynamics, heat transfer and reduction, the cohesion zone, and the balance equilibrium model. On the basis of these models, it details a method for the analytical study of the blast-furnace process, which essentially complements the experimental methods used in practice. Examples of the solution of practical problems of blast furnace smelting are also provided, and the mathematical models highlighted here can be used in research and design institutes, at metallurgical enterprises and for higher education institutions in the training of students in metallurgical specialties.

In order to reduce the cost of running blast furnaces (BFs), injected pulverized coal is used rather than coke to fire BFs. As a result of this, unburned fine materials are blown with the gas into the bosh and dead man areas with possible detrimental effects on gas flow and permeability of the coke column. The capacity of the furnace to consume these particles by solution loss is probably one of the limitations to coal injection. It is, therefore, important to understand the physicochemical and aerodynamic behaviour of fines including the change of in-furnace phenomena.The Committee of Pulverized Coal Combustion and In-Furnace Reaction in BF was set up in 1993 as a cooperative research of the Japan Society for the Promotion of Science (JSPS) and the Iron and Steel Institute (ISIJ) to evaluate research initiative into this problem.This book reports on the JSPS/ISIJ Committee's activities and describes the interpretation of findings drawn from combustion experiments and the results of live furnace applications, and furnace performance.