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Blast furnace

Type of furnace used for smelting to produce industrial metals

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Former blast furnace #2 belonging to the now defunct company Altos Hornos del Mediterráneo S.A. (Mediterranean Blast Furnaces Ltd.), located in Port of Sagunto , Valencian Community, Spain. The compan
Diego Delso · CC BY-SA 4.0

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In a blast furnace, fuel (coke), ores, and flux (limestone) are continuously supplied through the top of the furnace, while a hot blast of (sometimes oxygen-enriched) air is blown into the lower section of the furnace through a series of pipes called tuyeres, so that the chemical reactions take place throughout the furnace as the material falls downward. The end products are usually molten metal and slag phases tapped from the bottom, and flue gases exiting from the top. The downward flow of the ore along with the flux in contact with an upflow of hot, carbon monoxide-rich combustion gases is a countercurrent exchange and chemical reaction process.

In contrast, air furnaces (such as reverberatory furnaces) are naturally aspirated, usually by the convection of hot gases in a chimney flue. According to this broad definition, bloomeries for iron, blowing houses for tin, and smelt mills for lead would be classified as blast furnaces. However, the term has usually been limited to those used for smelting iron ore to produce pig iron, an intermediate material used in the production of commercial iron and steel, and the shaft furnaces used in combination with sinter plants in base metals smelting.

The process of using blast furnaces has its origin in as early as 5th century BC China, but only spread to the rest of Eurasia in the middle ages. They only became the dominant form of metal smelting with advances in Coking and furnace design during the Early Modern period. Blast furnaces are estimated to have been responsible for over 4% of global greenhouse gas emissions between 1900 and 2015, and are difficult to decarbonize.

Process engineering and chemistry

Blast furnaces operate on the principle of chemical reduction whereby carbon monoxide converts iron oxides to elemental iron.

Blast furnaces differ from bloomeries and reverberatory furnaces in that in a blast furnace, flue gas is in direct contact with the ore and iron, allowing carbon monoxide to diffuse into the ore and reduce the iron oxide. The blast furnace operates as a countercurrent exchange process whereas a bloomery does not. Another difference is that bloomeries operate as a batch process whereas blast furnaces operate continuously for long periods. Continuous operation is also preferred because blast furnaces are difficult to start and stop. Also, the carbon in pig iron lowers the melting point below that of steel or pure iron; in contrast, iron does not melt in a bloomery.

Silica has to be removed from the pig iron. It reacts with calcium oxide (burned limestone) and forms silicates, which float to the surface of the molten pig iron as slag. Historically, iron was produced with charcoal to prevent sulfur contamination.

In a blast furnace, a downward-moving column of ore, flux, coke (or charcoal) and their reaction products must be sufficiently porous for the flue gas to pass through, upwards. To ensure this permeability the particle size of the coke or charcoal is of great relevance. Therefore, the coke must be strong enough so it will not be crushed by the weight of the material above it. Besides the physical strength of its particles, the coke must also be low in sulfur, phosphorus, and ash.

The main chemical reaction producing the molten iron is:

Fe2O3 + 3CO → 2Fe + 3CO2

This reaction might be divided into multiple steps, with the first being that preheated air blown into the furnace reacts with the carbon in the form of coke to produce carbon monoxide and heat:

2 C(s) + O2(g) → 2 CO(g)

Hot carbon monoxide is the reducing agent for the iron ore and reacts with the iron oxide to produce molten iron and carbon dioxide. Depending on the temperature in the different parts of the furnace (warmest at the bottom) the iron is reduced in several steps. At the top, where the temperature usually is in the range between 200 and 700 °C (392 and 1,292 °F), the iron oxide is partially reduced to iron(II,III) oxide, Fe3O4.

3 Fe2O3(s) + CO(g) → 2 Fe3O4(s) + CO2(g)

The temperatures 850 °C (1,560 °F), further down in the furnace, the iron(II,III) is reduced further to iron(II) oxide:

Fe3O4(s) + CO(g) → 3 FeO(s) + CO2(g)

Hot carbon dioxide, unreacted carbon monoxide, and nitrogen from the air pass up through the furnace as fresh feed material travels down into the reaction zone. As the material travels downward, the counter-current gases both preheat the feed charge and decompose the limestone to calcium oxide and carbon dioxide:

CaCO3(s) → CaO(s) + CO2(g)

The calcium oxide formed by decomposition reacts with various acidic impurities in the iron (notably silica), to form a fayalitic slag which is essentially calcium silicate, CaSiO
3:

SiO2 + CaO → CaSiO3

As the iron(II) oxide moves down to the area with higher temperatures, ranging up to 1,200 °C (2,190 °F) degrees, it is reduced further to iron metal:

FeO(s) + CO(g) → Fe(s) + CO2(g)

The carbon dioxide formed in this process is re-reduced to carbon monoxide by the coke:

C(s) + CO2(g) → 2 CO(g)

The temperature-dependent equilibrium controlling the gas atmosphere in the furnace is called the Boudouard reaction:

2CO ⇌ CO2 + C

The pig iron produced by the blast furnace has a relatively high carbon content of around 4–5% and usually contains too much sulphur, making it very brittle, and of limited immediate commercial use. Some pig iron is used to make cast iron. The majority of pig iron produced by blast furnaces undergoes further processing to reduce the carbon and sulphur content and produce various grades of steel used for construction materials, automobiles, ships and machinery. Desulphurisation usually takes place during the transport of the liquid steel to the steelworks. This is done by adding calcium oxide, which reacts with the iron sulfide contained in the pig iron to form calcium sulfide (called lime desulfurization). In a further process step, the so-called basic oxygen steelmaking, the carbon is oxidized by blowing oxygen onto the liquid pig iron to form crude steel.

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