Blast furnaces process

2. BLAST FURNACE
• A BLAST FURNACE IS A HIGH-TEMPERATURE INDUSTRIAL FURNACE
WHERE IRON ORE, COKE (CARBON-RICH FUEL), AND LIMESTONE ARE
CHEMICALLY PROCESSED TO PRODUCE MOLTEN IRON USED FOR
MAKING STEEL AND OTHER PRODUCTS.
• THE MAIN PURPOSE OF A BLAST FURNACE IS TO CONVERT IRON ORE
INTO MOLTEN IRON THROUGH A CHEMICAL REDUCTION PROCESS,
WHICH IS ESSENTIAL FOR PRODUCING STEEL AND VARIOUS INDUSTRIAL
GOODS.

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4. materials Quantity in kgs
Iron ore/sinter/pellets (+60% Fe) 2000-2500
coke 450-550
Pulverised coal(for injection through tuyeres) 50-200
Lime stone 300-400
Air (hot blast) 4000-5000

5. • IRON ORE IN A BLAST FURNACE SERVES AS THE RAW MATERIAL CONTAINING IRON
OXIDES. IT UNDERGOES REDUCTION WITH COKE (CARBON-RICH FUEL) AT HIGH
TEMPERATURES, RESULTING IN THE PRODUCTION OF MOLTEN IRON AND SLAG.
THIS MOLTEN IRON IS USED FOR MAKING STEEL AND OTHER INDUSTRIAL
PRODUCTS, WHILE THE SLAG HELPS REMOVE IMPURITIES FROM THE IRON ORE.

6. • COKE IS A CARBON-RICH FUEL USED IN BLAST FURNACES. IT SERVES AS
A HEAT SOURCE AND REDUCING AGENT, REACTING WITH OXYGEN IN
THE IRON ORE TO PRODUCE CARBON MONOXIDE. THIS CARBON
MONOXIDE THEN FACILITATES THE REDUCTION OF IRON OXIDES TO
MOLTEN IRON DURING THE SMELTING PROCESS.

7. • LIMESTONE IN A BLAST FURNACE ACTS AS A FLUXING AGENT. IT HELPS REMOVE
IMPURITIES BY REACTING WITH THEM TO FORM SLAG, WHICH FLOATS ON THE
MOLTEN IRON. THIS PROCESS AIDS IN PURIFYING THE IRON AND IMPROVING THE
EFFICIENCY OF THE REDUCTION REACTION.

8. •
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9. 1.LOAD THE FURNACE: IRON ORE, COKE, AND LIMESTONE ARE LOADED
INTO THE FURNACE IN LAYERS.
2.ADD HEAT: HOT AIR IS BLOWN INTO THE FURNACE TO MAKE IT
EXTREMELY HOT.
3.CHEMICAL REACTIONS: THE COKE BURNS WITH THE OXYGEN IN THE
AIR, CREATING CARBON MONOXIDE. THIS GAS REACTS WITH IRON
ORE, TURNING IT INTO MOLTEN IRON AND PRODUCING SLAG.
4.COLLECT MOLTEN IRON: THE MOLTEN IRON SINKS TO THE BOTTOM
OF THE FURNACE AND IS COLLECTED.
5.REMOVE SLAG: THE LIGHTER SLAG FLOATS ON TOP OF THE IRON
AND IS REMOVED.
6.CONTINUOUS PROCESS: THE FURNACE RUNS CONTINUOUSLY, WITH
MATERIALS ADDED AT THE TOP AND MOLTEN IRON AND SLAG TAKEN
OUT AT INTERVALS.
• THIS PROCESS TRANSFORMS RAW MATERIALS INTO MOLTEN IRON,
WHICH CAN BE USED TO MAKE STEEL.

10. 1.Raw Materials: Iron ore, coke, and limestone are
combined in specific proportions.
2.Heating: Hot air is blown into the furnace, raising the
temperature to around 2,000°C (3,632°F).
3.Reduction: Coke reacts with oxygen to produce carbon
monoxide, which reduces iron ore to molten iron.
4.Slag Formation: Limestone reacts with impurities to form
a floating slag layer.
5.Separation: Molten iron and slag are tapped off
separately, and the process is continuous.

11. • THE BLAST FURNACE IS A CRUCIAL INDUSTRIAL FURNACE WHERE IRON ORE,
ALONG WITH COKE AND LIMESTONE, UNDERGOES A COMPLEX CHEMICAL
PROCESS. THIS PROCESS RESULTS IN THE PRODUCTION OF MOLTEN IRON, WHICH
SERVES AS A VITAL RAW MATERIAL FOR VARIOUS INDUSTRIES, PARTICULARLY
STEELMAKING. THE USE OF COKE AS A REDUCING AGENT AND LIMESTONE AS A
FLUX HELPS EXTRACT PURE IRON WHILE REMOVING IMPURITIES. THIS FURNACE'S
EFFICIENCY AND VERSATILITY HAVE MADE IT A CORNERSTONE OF MODERN
INDUSTRIAL MANUFACTURING, PLAYING A CENTRAL ROLE IN SHAPING THE
MATERIALS THAT POWER OUR SOCIETIES