Fundamentals of blast furnace steelmaking (1967)

Panorama of blast furnaces of a metallurgical plant.

Iron ore or agglomerate.

Fluxes.

Coke.

Special device for unloading wagons.

An agglomeration plant where crushed and homogenized ore is sintered.

To obtain agglomeration charge, homogenized ore is fed from the warehouse to the mixing shop, as well as waste from metallurgical production - blast furnace dust, scale and limestone.

Coke breeze is used as fuel.

A conveyor belt feeds the materials to the mixer, where they are mixed and moistened.

Then the prepared charge is fed to the agglomeration machine by a drum feeder.

The agglomeration belt with the charge constantly moves under gas burners.

In this case, sulfur, which is a harmful impurity, burns out.

By the time the agglomeration belt is unloaded, the charge is sintered across the entire thickness of the layer.

The fluxed agglomerate is sorted and transported to the blast furnace shop.

Coke ovens, in which dry distillation of coal occurs.

Coal charge is loaded into coking chambers and after 10-14 hours, coke cake is produced.

After quenching and separation of fines, the coke is sent to the blast furnace shop.

Structures that are part of the blast furnace shop complex.

Blast furnace, dressed in a solid welded metal casing.

Casting yard.

Skip hoist bridge for feeding charge into the blast furnace.

Ore yard.

Blast furnace is a shaft-type furnace.

Cartoon explaining the structure of a blast furnace.

Cartoon explaining the structure of air tuyeres and their operation.

Air heaters.

Cartoon explaining the structure of an air heater and its operation.

Heated air under pressure is fed into the furnace through straight and ring pipelines through the air-conducting sleeves of the tuyere.

Tuyere devices.

Natural gas is supplied to the furnace via the main and ring pipelines and enters the combustion zone through tuyeres together with air.

Blast furnace shop control room.

The blast furnace loading equipment allows for feeding huge masses of ore, agglomerate, coke and fluxes into the furnace.

All feeding processes are automated.

The batch is loaded according to a specified program.

Loading relay.

The batch raised to the throat is loaded into the furnace via a charging device.

A cartoon explaining the operation of a charging device.

A cartoon explaining the blast furnace process.

Chemical processes occurring in a blast furnace.

Chemical composition of gas in the furnace during the blast furnace process.

A cartoon explaining the processes occurring with a piece of ore or agglomerate during heating.

Chemical formulas of the process.

Chemical processes occurring when the heating temperature increases to 900 degrees and higher.

At a temperature of about 1200 degrees, the gangue rock softens and begins to melt.

It consists of silica, which interacts with the calcium oxide of the flux, as well as with unreduced iron and manganese oxides, forming slag.

Chemical formulas of the process.

Simultaneously with iron, silicon, manganese and phosphorus are reduced, which pass into pig iron.

A cartoon explaining the chemical processes occurring during the separation of pig iron and slag in a blast furnace.

The slag and metal accumulating in the blast furnace are periodically tapped.

The slag tapholes are closed with slag stoppers.

Steel plug at the end of the slag stopper.

The taphole is opened and closed with compressed air.

The pig iron and slag residues are released through the pig iron taphole.

The pig iron taphole is opened with an electric drilling machine.

The pig iron stream flows into the ladles.

A rotary chute that allows pig iron to be poured into several ladles through one spout.

The pig iron taphole is closed with a single-cylinder electric gun.

A cartoon explaining the formation and chemical composition of blast furnace gas.

Cleaning of blast furnace gas.

Rough cleaning in dust collectors-grubers.

Medium cleaning in cyclones.

Fine cleaning in throttles and electrostatic precipitators.

The bulk of the pig iron is drained into a mixer, which serves to accumulate and mix the pig iron.

From the mixer, the pig iron is sent to steelmaking furnaces for steel processing.

Some of the pig iron is poured into molds on a casting machine.

The cooled pig iron is sent to the consumer in the form of ingots.

Open-hearth shop.

Cartoon explaining the structure of an open-hearth furnace.

Operation of an open-hearth furnace using the scrub-ore process.

After steel is tapped and before a new process begins, the furnace is inspected.

Compressed air is used to blow out any remaining slag and metal from the bottom.

Worn areas of the bottom and walls of the furnace are filled with magnesite powder.

Charging of the batch begins immediately after charging the furnace.

First, a layer of ore or agglomerate is loaded.

Cartoon explaining further loading of the furnace.

Ore is loaded with mandatory heating of each layer.

After the bulk material has been heated, scrub and steel scrap are fed into the furnace.

To speed up charging, the batch is loaded using two charging machines.

Additional heating of the scrap.

During heating, false thresholds of the charging windows are added and troughs for pouring iron are installed.

The steelmaker inspects the furnaces.

After the batch and scrap have been sufficiently heated, iron is poured into the furnace.

Cartoon explaining the process of steel smelting in an open-hearth furnace.

Chemical formulas characterizing the process.

Cartoon explaining the use of oxygen to intensify combustion and speed up the smelting process.

The smelting process is completed by deoxidizing with ferroalloys.

A steelmaker observes the smelting process.

In the production of alloy steels, alloying additives are introduced simultaneously with deoxidizers.

Cartoon explaining the effect of oxidizers on the smelting process.

Samples of metal readiness are taken.

Steel is released into ladles.

Electric furnace for producing high-alloy tool, heat-resistant and stainless steels.

The furnace is pulled out for loading.

Furnace loading from the top using a bucket.

Cartoon explaining the structure of an electric furnace.

At the steelmaker's command, the electrodes are lowered and the current is turned on.

Cartoon explaining the smelting process.

To facilitate dephosphorization, iron ore is added to the bath.

After some time, the primary slag is pumped out.

Most of the phosphorus oxidized during smelting is removed with it.

To obtain active slag, freshly burned lime is loaded into the furnace.

Adding an additional portion of ore promotes foaming of the slag, which is pumped out again.

Then the bath is allowed to boil without any additives under a thin layer of slag.

Cartoon explaining the process of metal deoxidation through slag.

Chemical formulas of the process.

Alloying elements are introduced in different ways, depending on their properties.

Nickel is practically not oxidized and can be introduced during the charging period.

Ferrochrome is oxidized, it is introduced after deoxidation.

Ferrovanadium is easily oxidized, therefore it is added 15-20 minutes before tapping the melt.

The smelted metal is tapped into ladles and sent for casting.

Oxygen converters.

The converter has a welded metal casing, lined on the inside.

A taphole for tapping metal and slag.

A tuyere for feeding oxygen.

The tuyere nozzle is screwed on.

Welding the nozzle to the tuyere.

The scrub is delivered to the converter in boxes made in the form of a scoop.

Liquid pig iron is fed from the mixer in ladles by an overhead crane.

The charge materials are added to the converter at the beginning of the melt, as well as during it.

The conveyor system feeds the charge into the feed bins.

Then the charge enters the weigh bin, from where it is poured into the converter through a receiving funnel and a retractable chute.

After the converter is completely loaded, the tuyere is lowered into it.

A cartoon explaining the process of melting in a converter.

Converter exhaust gases enter the gas cleaning system.

During the melting process, the temperature is measured and metal samples are taken.

During the draining, the steel is deoxidized and alloyed, and upon completion of the metal tapping, the slag is drained into a slag ladle.

The smelted metal is fed to the casting unit.

A cartoon explaining the pouring of steel from above.

Siphon pouring.

A cartoon explaining this type of pouring.

Continuous casting of steel.

A cartoon explaining the pouring of steel in this way and the use of a crystallizer.

The ingot is cut into pieces of measured length.

Alternating frames from the film.