Blast Furnace Ironmaking
A fully integrated service that ensures your steel plant project is expertly designed, constructed, and ready for seamless operation. Let us handle every detail, from engineering to training, so you can focus on production success.
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One-Stop Blast Furnace Ironmaking Solutions
SME Group provides turnkey and one-stop services to build blast furnace ironmaking plants from the ground up. Sepecializing in medium and small blast furnaces, we deliver all process services for the project, including the plan design, manufacturing, construction, installation, and commissioning.
The quality of design and construction of the project will determine the operational efficiency of the blast furnace ironmaking system. SME’s project team has rich experience in ironmaking projects and boasts various engineers knowledgeable in blast furnace & hot blast stove, energy & power, pollution control, and automation & communication sectors.
Blast Furnace Ironmaking Process
The blast furnace is the core unit in the ironmaking process, capable of converting fine iron ore and fluxes into crude iron, also known as pig iron.
Iron ore, fuel, and fluxes are charged from the top of the furnace and move downward, while preheated air is blown in at the bottom, combusting the fuel and generating a large volume of high-temperature reducing gases that rise upward. The raw materials undergo a series of physical and chemical processes, including heating, reduction, melting, slag formation, carburization, and desulfurization. Ultimately, liquid slag and pig iron are produced.
The ironmaking process is a comprehensive engineering discipline that involves multiple systems. Process of design should fully consider energy recovery and minimal influence on plant environmental impact. The main systems are listed blow.
- Sintering Process
- Material Feeding System
- Charging System
- Combustion Unit
- Air Blowing System
- Gas Recovery and Dedusting
- Molten Iron and Slag Handling
- Tapping System
- Injection System
- Power Systems Supporting These Subsystems
Raw Materials in Blast Furnace Production
The primary raw materials for blast furnace production include iron ore and its substitutes, manganese ore, fuels, and fluxes.
- Iron Ore:
- Natural Ore: High-grade ore with an iron content above 50% can be directly charged into the furnace.
- Processed Ore: Low-grade ore (30%-45% iron) requires beneficiation and pelletizing to form artificial rich ore for efficient furnace use.
- Iron Ore Substitutes: Recycled materials like blast furnace dust, basic oxygen furnace dust, mill scale, sulfuric acid slag, and high-iron tailings from nonferrous metal processing are often added to the sintering raw mix.
- Manganese Ore: Typically used only when producing ferroalloys such as high-manganese pig iron.
Products and By-Products
Our blast furnace plants are designed to produce high-quality pig iron, meeting diverse industry demands:
- Steelmaking Iron: For further refining in steel production.
- Casting Iron: Ideal for machine parts, tools, and ductile iron manufacturing.
- Specialty Pig Iron: Customized for ferroalloy production, including manganese and silicon irons.
We also ensure sustainable by-product utilization:
- Slag: Converted into cement raw materials, insulation materials, or lightweight aggregates.
- Blast Furnace Gas: Used as an energy source for heating stoves, boilers, and furnaces.
- Dust: Recovered as sinter feed to maximize material usage.
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